Custom Tactical Helmet in Tencel Lyocell with Smocking

Custom Tactical Helmet — Tencel Lyocell with Smocking

We build tactical helmet programmes from a tech pack or a physical reference sample. This Tencel Lyocell 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, smocking 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 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

• Chenille Embroidery — available on Tencel Lyocell, quoted per position and per colour.
• Yarn Dyeing — available on Tencel Lyocell, quoted per position and per colour.
• Laser Engraving — available on Tencel Lyocell, quoted per position and per colour.
• Tonal Embroidery — available on Tencel Lyocell, quoted per position and per colour.
• Shirring — available on Tencel Lyocell, quoted per position and per colour.
• All-Over Sublimation — available on Tencel Lyocell, quoted per position and per colour.
• Contrast Stitching — available on Tencel Lyocell, 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 Tencel Lyocell-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with smocking applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Food Processing — tactical helmet uniforms, staff wear or resale programmes
• Maternity and Baby Care — tactical helmet uniforms, staff wear or resale programmes
• Streetwear Brands — tactical helmet uniforms, staff wear or resale programmes
• Kidswear Subscription Boxes — tactical helmet uniforms, staff wear or resale programmes
• Film and TV Production — tactical helmet 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 tactical helmet 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.

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.

Do you provide compliance documents?

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

What is the minimum order quantity?

Standard programmes start at 50 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.

Start your tactical helmet programme

Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.