Custom Hat Sun in Power Mesh with Ultrasonic Welding

Custom Hat Sun — Power Mesh with Ultrasonic Welding

We build hat sun programmes from a tech pack or a physical reference sample. This Power Mesh 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, ultrasonic welding 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 unclear responsibility when a defect shows up after washing. 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

• Piping and Binding — available on Power Mesh, quoted per position and per colour.
• Seam Sealing — available on Power Mesh, quoted per position and per colour.
• Tonal Embroidery — available on Power Mesh, quoted per position and per colour.
• Bonding Construction — available on Power Mesh, quoted per position and per colour.
• Embossing — available on Power Mesh, quoted per position and per colour.
• Sequin Work — available on Power Mesh, quoted per position and per colour.
• Custom Button — available on Power Mesh, 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 Power Mesh-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with ultrasonic welding applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Airlines and Cruise Lines — hat sun uniforms, staff wear or resale programmes
• Dental and Veterinary Clinics — hat sun uniforms, staff wear or resale programmes
• Chemical and Oil & Gas — hat sun uniforms, staff wear or resale programmes
• Ski and Snowboard Resorts — hat sun uniforms, staff wear or resale programmes
• Pet Care and Grooming — hat sun 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 sun batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

How long does sampling take?

A first prototype is typically ready in 14 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.

Do you provide compliance documents?

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

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.

Start your hat sun 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.