Custom Hat Sun in Flannel with DTG Digital Printing

Custom Hat Sun — Flannel with DTG Digital Printing

We build hat sun programmes from a tech pack or a physical reference sample. This Flannel 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, dtg digital printing 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 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 Flannel, quoted per position and per colour.
• Shirring — available on Flannel, quoted per position and per colour.
• Care Label — available on Flannel, quoted per position and per colour.
• Chain Stitch Embroidery — available on Flannel, quoted per position and per colour.
• Screen Printing — available on Flannel, quoted per position and per colour.
• DTF Film Printing — available on Flannel, quoted per position and per colour.
• Glow-in-the-Dark Printing — available on Flannel, 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 Flannel-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with dtg digital printing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Police and Fire Departments — hat sun uniforms, staff wear or resale programmes
• Esports and Gaming — hat sun uniforms, staff wear or resale programmes
• Hospitality and Hotels — hat sun uniforms, staff wear or resale programmes
• Real Estate Agencies — hat sun uniforms, staff wear or resale programmes
• Food Processing — 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

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.

What is the minimum order quantity?

Standard programmes start at 150 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.

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.

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.