Custom Hat Visor in Corduroy with Ultrasonic Welding

Custom Hat Visor — Corduroy with Ultrasonic Welding

We build hat visor programmes from a tech pack or a physical reference sample. This Corduroy 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 long lead times that miss the selling season. 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

• Care Label — available on Corduroy, quoted per position and per colour.
• Flocking — available on Corduroy, quoted per position and per colour.
• Pantone Color Matching — available on Corduroy, quoted per position and per colour.
• Garment Dyeing — available on Corduroy, quoted per position and per colour.
• Distressed Finish — available on Corduroy, quoted per position and per colour.
• Foil Printing — available on Corduroy, quoted per position and per colour.
• Tie-Dye Wash — available on Corduroy, 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 Corduroy-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

• Esports and Gaming — hat visor uniforms, staff wear or resale programmes
• Outdoor and Hiking — hat visor uniforms, staff wear or resale programmes
• Religious and Community — hat visor uniforms, staff wear or resale programmes
• Police and Fire Departments — hat visor uniforms, staff wear or resale programmes
• Spas and Salons — hat visor 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 visor 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 is the minimum order quantity?

Standard programmes start at 100 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.

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.

How long does sampling take?

A first prototype is typically ready in 7 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.

Start your hat visor 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.