Custom Hat Balaclava in Velour with DTF Film Printing

Custom Hat Balaclava — Velour with DTF Film Printing

We build hat balaclava programmes from a tech pack or a physical reference sample. This Velour 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 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

• Piece Dyeing — available on Velour, quoted per position and per colour.
• Enzyme Wash — available on Velour, quoted per position and per colour.
• All-Over Sublimation — available on Velour, quoted per position and per colour.
• Woven Label — available on Velour, quoted per position and per colour.
• Distressed Finish — available on Velour, quoted per position and per colour.
• Chain Stitch Embroidery — available on Velour, quoted per position and per colour.
• Yarn Dyeing — available on Velour, 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 Velour-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

• Manufacturing Plants — hat balaclava uniforms, staff wear or resale programmes
• Real Estate Agencies — hat balaclava uniforms, staff wear or resale programmes
• Boutique and Independent Labels — hat balaclava uniforms, staff wear or resale programmes
• Religious and Community — hat balaclava uniforms, staff wear or resale programmes
• Theater and Performance — hat balaclava 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 balaclava batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

Do you provide compliance documents?

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

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.

What is the minimum order quantity?

Standard programmes start at 500 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.

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 3 days each.

Start your hat balaclava programme

Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.