Custom Disposable Cap in Merino Wool with Bonding Construction

Custom Disposable Cap — Merino Wool with Bonding Construction

We build disposable cap 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, bonding construction 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: packaging that arrives crushed and unsellable, or no reliable way to track a order once it enters production. 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

• Custom Button — available on Merino Wool, quoted per position and per colour.
• Garment Dyeing — available on Merino Wool, quoted per position and per colour.
• Puff Printing — available on Merino Wool, quoted per position and per colour.
• Placement Printing — available on Merino Wool, quoted per position and per colour.
• Seam Sealing — available on Merino Wool, quoted per position and per colour.
• Pleating — available on Merino Wool, quoted per position and per colour.
• Ultrasonic Welding — 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 bonding construction applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Warehousing and Logistics — disposable cap uniforms, staff wear or resale programmes
• Promotional Marketing — disposable cap uniforms, staff wear or resale programmes
• Ski and Snowboard Resorts — disposable cap uniforms, staff wear or resale programmes
• Airlines and Cruise Lines — disposable cap uniforms, staff wear or resale programmes
• Maternity and Baby Care — disposable cap 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 disposable cap 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 100 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 10 working days after the tech pack is confirmed, including fabric sourcing if the base cloth is not in our stock library. Revisions add about 3 days each.

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.

Start your disposable cap 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.