Custom Hat Straw in Down-Proof Nylon with Quilting

Custom Hat Straw — Down-Proof Nylon with Quilting

We build hat straw programmes from a tech pack or a physical reference sample. This Down-Proof Nylon 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, quilting 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 suppliers who disappear once the deposit is paid. 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

• Laser Cutting — available on Down-Proof Nylon, quoted per position and per colour.
• Screen Printing — available on Down-Proof Nylon, quoted per position and per colour.
• Chain Stitch Embroidery — available on Down-Proof Nylon, quoted per position and per colour.
• Heat Transfer Printing — available on Down-Proof Nylon, quoted per position and per colour.
• Yarn Dyeing — available on Down-Proof Nylon, quoted per position and per colour.
• Snow Wash — available on Down-Proof Nylon, quoted per position and per colour.
• Tie-Dye Wash — available on Down-Proof Nylon, 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 Down-Proof Nylon-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with quilting applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Trade Shows and Exhibitions — hat straw uniforms, staff wear or resale programmes
• Film and TV Production — hat straw uniforms, staff wear or resale programmes
• Tennis Academies — hat straw uniforms, staff wear or resale programmes
• Music Bands and Touring — hat straw uniforms, staff wear or resale programmes
• Fashion Brands and Labels — hat straw 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 straw batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

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.

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 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.

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.

Start your hat straw programme

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