Custom Hat Sun in Waffle Knit with DTF Film Printing

Custom Hat Sun — Waffle Knit with DTF Film Printing

We build hat sun programmes from a tech pack or a physical reference sample. This Waffle Knit 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, dtf film 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: packaging that arrives crushed and unsellable, 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

• Hangtag and Packaging — available on Waffle Knit, quoted per position and per colour.
• Beading and Embroidery — available on Waffle Knit, quoted per position and per colour.
• Sequin Work — available on Waffle Knit, quoted per position and per colour.
• 3D Puff Embroidery — available on Waffle Knit, quoted per position and per colour.
• Debossing — available on Waffle Knit, quoted per position and per colour.
• Bonding Construction — available on Waffle Knit, quoted per position and per colour.
• Rhinestone Application — available on Waffle Knit, 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 Waffle Knit-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with dtf film printing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Airsoft and Paintball Clubs — hat sun uniforms, staff wear or resale programmes
• Veterinary Clinics — hat sun uniforms, staff wear or resale programmes
• Kidswear Subscription Boxes — hat sun uniforms, staff wear or resale programmes
• Airlines and Cruise Lines — hat sun uniforms, staff wear or resale programmes
• Cleaning and Janitorial — 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.

What is the minimum order quantity?

Standard programmes start at 500 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.

Start your hat sun programme

Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.