Custom Aviator in Power Mesh with Laser Cutting

Custom Aviator — Power Mesh with Laser Cutting

We build aviator programmes from a tech pack or a physical reference sample. This Power Mesh 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, laser cutting 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: inconsistent sizing between production runs, or packaging that arrives crushed and unsellable. 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

• Custom Drawcord — available on Power Mesh, quoted per position and per colour.
• Stone Wash — available on Power Mesh, quoted per position and per colour.
• Rhinestone Application — available on Power Mesh, quoted per position and per colour.
• Foil Printing — available on Power Mesh, quoted per position and per colour.
• DTF Film Printing — available on Power Mesh, quoted per position and per colour.
• Placement Printing — available on Power Mesh, quoted per position and per colour.
• Custom Zip Puller — available on Power Mesh, 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 Power Mesh-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with laser cutting applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Dance and Ballet Schools — 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
• Esports and Gaming — aviator uniforms, staff wear or resale programmes
• Kidswear Subscription Boxes — 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

What is the minimum order quantity?

Standard programmes start at 150 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 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 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

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.