Custom Boonie in Taffeta with Tonal Embroidery

Custom Boonie — Taffeta with Tonal Embroidery

We build boonie programmes from a tech pack or a physical reference sample. This Taffeta 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, tonal 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: 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

• DTF Film Printing — available on Taffeta, quoted per position and per colour.
• Debossing — available on Taffeta, quoted per position and per colour.
• Contrast Stitching — available on Taffeta, quoted per position and per colour.
• Smocking — available on Taffeta, quoted per position and per colour.
• Seam Sealing — available on Taffeta, quoted per position and per colour.
• Dye-Sublimation Printing — available on Taffeta, quoted per position and per colour.
• Flocking — available on Taffeta, 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 Taffeta-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with tonal embroidery applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Universities — boonie uniforms, staff wear or resale programmes
• Airlines and Cruise Lines — boonie uniforms, staff wear or resale programmes
• Government and Municipal — boonie uniforms, staff wear or resale programmes
• Motorcycle and Motorsport — boonie uniforms, staff wear or resale programmes
• Esports and Gaming — boonie 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 boonie 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 200 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.

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.

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.

Start your boonie programme

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