Custom Theatrical Costume in Merino Wool with Applique Embroidery

Custom Theatrical Costume — Merino Wool with Applique Embroidery

We build theatrical costume programmes from a tech pack or a physical reference sample. This Merino Wool 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, applique embroidery 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: color drift between lab dips and bulk fabric, or minimum order quantities far above what a growing brand can absorb. 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

• Reflective Printing — available on Merino Wool, quoted per position and per colour.
• Tonal Embroidery — available on Merino Wool, quoted per position and per colour.
• Distressed Finish — available on Merino Wool, quoted per position and per colour.
• Ultrasonic Welding — available on Merino Wool, quoted per position and per colour.
• Care Label — available on Merino Wool, quoted per position and per colour.
• Acid Wash — available on Merino Wool, quoted per position and per colour.
• Quilting — available on Merino Wool, 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 Merino Wool-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with applique embroidery applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Laboratories and Pharma — theatrical costume uniforms, staff wear or resale programmes
• Banking and Finance — theatrical costume uniforms, staff wear or resale programmes
• Esports and Gaming — theatrical costume uniforms, staff wear or resale programmes
• Chemical and Oil & Gas — theatrical costume uniforms, staff wear or resale programmes
• Agriculture and Farming — theatrical costume 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 theatrical costume batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

What is the minimum order quantity?

Standard programmes start at 150 pieces per style and colour. We can split sizes across a size set, and for first orders we often accept a mixed-colour run to help you test the market.

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 4 days each.

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 is shipping handled?

We quote EXW, FOB, CIF and DDP. Consolidated sea freight is the default for bulk programmes, with air or express options when a launch date is at risk.

Start your theatrical costume programme

Send us your tech pack or even a rough sketch — we will come back with fabric options, a costed sample plan and a realistic production calendar.