Custom Hat Balaclava in Cupro with Screen Printing

Custom Hat Balaclava — Cupro with Screen Printing

We build hat balaclava programmes from a tech pack or a physical reference sample. This Cupro 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, screen 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: inconsistent sizing between production runs, or suppliers who disappear once the deposit is paid. 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

• Chenille Embroidery — available on Cupro, quoted per position and per colour.
• 3D Puff Embroidery — available on Cupro, quoted per position and per colour.
• Piece Dyeing — available on Cupro, quoted per position and per colour.
• Flocking — available on Cupro, quoted per position and per colour.
• Yarn Dyeing — available on Cupro, quoted per position and per colour.
• Snow Wash — available on Cupro, quoted per position and per colour.
• Sequin Work — available on Cupro, 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 Cupro-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with screen printing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Sports Teams and Clubs — hat balaclava uniforms, staff wear or resale programmes
• Aviation and Airlines — hat balaclava uniforms, staff wear or resale programmes
• Streetwear Brands — hat balaclava uniforms, staff wear or resale programmes
• Construction Sites — hat balaclava uniforms, staff wear or resale programmes
• Film and TV Production — 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

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.

Do you provide compliance documents?

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

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 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 4 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.