Custom Hat Bucket in Corduroy with Yarn Dyeing

Custom Hat Bucket — Corduroy with Yarn Dyeing

We build hat bucket programmes from a tech pack or a physical reference sample. This Corduroy version is developed for brands that need a repeatable specification: the same cloth, the same hand feel and the same fit on every reorder. Fabric, trims, yarn dyeing and packaging are all specifiable, so the garment stays consistent across seasons and across production runs.

Most buyers come to us after one of these problems: unclear responsibility when a defect shows up after washing, or color drift between lab dips and bulk fabric. Our response is to fix the specification first — fabric weight, shrinkage allowance, stitch density and tolerance — before a single bulk metre is cut.

Specification

What you can customise

• Woven Label — available on Corduroy, quoted per position and per colour.
• Acid Wash — available on Corduroy, quoted per position and per colour.
• Garment Dyeing — available on Corduroy, quoted per position and per colour.
• Tie-Dye Wash — available on Corduroy, quoted per position and per colour.
• Padding and Wadding — available on Corduroy, quoted per position and per colour.
• Embossing — available on Corduroy, quoted per position and per colour.
• Beading and Embroidery — available on Corduroy, quoted per position and per colour.

How we produce it

1. Tech pack review and fabric confirmation
2. Lab dips or print strike-off for approval
3. Pattern making, grading and a Corduroy-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with yarn dyeing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Restaurants and Cafes — hat bucket uniforms, staff wear or resale programmes
• Promotional Marketing — hat bucket uniforms, staff wear or resale programmes
• Beauty and Cosmetics — hat bucket uniforms, staff wear or resale programmes
• Kidswear Subscription Boxes — hat bucket uniforms, staff wear or resale programmes
• Chemical and Oil & Gas — hat bucket uniforms, staff wear or resale programmes

Quality control

Every bulk order is checked against the approved sample for shade, hand feel, measurements and workmanship. We record shrinkage, colour fastness and seam strength on the first bulk lot and hold the data as the reference for reorders, so hat bucket batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

What file formats do you need for artwork?

Vector files (AI, EPS, PDF) give the best print and embroidery results. For raster artwork please supply at least 300 dpi at the final print size. We digitise embroidery files in-house and return a sew-out photo for approval.

Do you provide compliance documents?

We can arrange OEKO-TEX, GOTS, BSCI, WRAP and ISO documentation as well as third-party testing reports for OEKO-TEX Standard 100, and we support REACH, CPSIA and Prop 65 declarations for the relevant markets.

Can you match a specific colour?

Yes. Send us a Pantone TCX reference or a physical swatch. We return lab dips for approval and hold bulk shade within the agreed tolerance band before cutting.

How long does sampling take?

A first prototype is typically ready in 7 working days after the tech pack is confirmed, including fabric sourcing if the base cloth is not in our stock library. Revisions add about 5 days each.

Start your hat bucket programme

Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.