Custom Hat Balaclava in Corduroy with Puff Printing

Custom Hat Balaclava — Corduroy with Puff Printing

We build hat balaclava 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, puff 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: packaging that arrives crushed and unsellable, or unclear responsibility when a defect shows up after washing. 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

• Heat Transfer Printing — available on Corduroy, quoted per position and per colour.
• Applique Embroidery — available on Corduroy, quoted per position and per colour.
• Shirring — available on Corduroy, quoted per position and per colour.
• Pantone Color Matching — available on Corduroy, quoted per position and per colour.
• Ruching — available on Corduroy, quoted per position and per colour.
• Woven Label — available on Corduroy, quoted per position and per colour.
• Laser Cutting — 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 puff printing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Trade Shows and Exhibitions — hat balaclava uniforms, staff wear or resale programmes
• Mining Operations — hat balaclava uniforms, staff wear or resale programmes
• Kidswear Subscription Boxes — hat balaclava uniforms, staff wear or resale programmes
• Boutique and Independent Labels — hat balaclava uniforms, staff wear or resale programmes
• Airlines and Cruise Lines — 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

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 is the minimum order quantity?

Standard programmes start at 300 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 10 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.

Start your hat balaclava programme

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