Custom Hat Sun in Merino Wool with Stone Wash

Custom Hat Sun — Merino Wool with Stone Wash

We build hat sun programmes from a tech pack or a physical reference sample. This Merino Wool 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, stone wash 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: long lead times that miss the selling season, or inconsistent sizing between production runs. 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

• Quilting — available on Merino Wool, quoted per position and per colour.
• Acid Wash — available on Merino Wool, quoted per position and per colour.
• Snow Wash — available on Merino Wool, quoted per position and per colour.
• Contrast Stitching — available on Merino Wool, quoted per position and per colour.
• Glow-in-the-Dark Printing — available on Merino Wool, quoted per position and per colour.
• Yarn Dyeing — available on Merino Wool, quoted per position and per colour.
• Puff Printing — available on Merino Wool, 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 Merino Wool-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with stone wash applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Kids and Toddlerwear — hat sun uniforms, staff wear or resale programmes
• Chemical and Oil & Gas — hat sun uniforms, staff wear or resale programmes
• Electronics Assembly — hat sun uniforms, staff wear or resale programmes
• Fashion Brands and Labels — hat sun uniforms, staff wear or resale programmes
• Kidswear Subscription Boxes — 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 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.

How long does sampling take?

A first prototype is typically ready in 12 working days after the tech pack is confirmed, including fabric sourcing if the base cloth is not in our stock library. Revisions add about 5 days each.

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.