Custom Aviator in Pima Cotton with DTF Film Printing

Custom Aviator — Pima Cotton with DTF Film Printing

We build aviator programmes from a tech pack or a physical reference sample. This Pima Cotton 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: long lead times that miss the selling season, or color drift between lab dips and bulk fabric. 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

• Applique Embroidery — available on Pima Cotton, quoted per position and per colour.
• Seam Sealing — available on Pima Cotton, quoted per position and per colour.
• Chain Stitch Embroidery — available on Pima Cotton, quoted per position and per colour.
• Shirring — available on Pima Cotton, quoted per position and per colour.
• Reflective Printing — available on Pima Cotton, quoted per position and per colour.
• Custom Zip Puller — available on Pima Cotton, quoted per position and per colour.
• Laser Engraving — available on Pima Cotton, 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 Pima Cotton-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

• Construction Sites — aviator uniforms, staff wear or resale programmes
• Motorcycle and Motorsport — aviator uniforms, staff wear or resale programmes
• Pet Care and Grooming — aviator uniforms, staff wear or resale programmes
• Film and TV Production — aviator uniforms, staff wear or resale programmes
• Ski and Snowboard Resorts — aviator 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 aviator 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.

Do you provide compliance documents?

We can arrange OEKO-TEX, GOTS, BSCI, WRAP and ISO documentation as well as third-party testing reports for ISO 9001, and we support REACH, CPSIA and Prop 65 declarations for the relevant markets.

Start your aviator programme

Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.