Custom Aviator in Denim with Ribbed Cuff and Hem

Custom Aviator — Denim with Ribbed Cuff and Hem

We build aviator programmes from a tech pack or a physical reference sample. This Denim 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, ribbed cuff and hem 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: color drift between lab dips and bulk fabric, 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

• Distressed Finish — available on Denim, quoted per position and per colour.
• Padding and Wadding — available on Denim, quoted per position and per colour.
• Chenille Embroidery — available on Denim, quoted per position and per colour.
• Chain Stitch Embroidery — available on Denim, quoted per position and per colour.
• Pleating — available on Denim, quoted per position and per colour.
• Garment Dyeing — available on Denim, quoted per position and per colour.
• Yarn Dyeing — available on Denim, 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 Denim-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with ribbed cuff and hem applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Film and TV Production — aviator uniforms, staff wear or resale programmes
• Military and Tactical — aviator uniforms, staff wear or resale programmes
• Trade Shows and Exhibitions — aviator uniforms, staff wear or resale programmes
• Mining Operations — aviator uniforms, staff wear or resale programmes
• Event Management — 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

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.

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.

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.

Start your aviator programme

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