Custom Ear Muffs & Eye Masks in Jersey Knit with Ultrasonic Welding for Private Labels

Custom Ear Muffs & Eye Masks — Jersey Knit with Ultrasonic Welding

We build ear muffs & eye masks programmes from a tech pack or a physical reference sample. This Jersey Knit 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, ultrasonic welding 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 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

• Beading and Embroidery — available on Jersey Knit, quoted per position and per colour.
• Chain Stitch Embroidery — available on Jersey Knit, quoted per position and per colour.
• Hangtag and Packaging — available on Jersey Knit, quoted per position and per colour.
• Chenille Embroidery — available on Jersey Knit, quoted per position and per colour.
• Laser Engraving — available on Jersey Knit, quoted per position and per colour.
• Ultrasonic Welding — available on Jersey Knit, quoted per position and per colour.
• Ruching — available on Jersey Knit, 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 Jersey Knit-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with ultrasonic welding applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Cycling and Triathlon — ear muffs & eye masks uniforms, staff wear or resale programmes
• Aviation and Airlines — ear muffs & eye masks uniforms, staff wear or resale programmes
• Surf and Swim Brands — ear muffs & eye masks uniforms, staff wear or resale programmes
• Maternity and Baby Care — ear muffs & eye masks uniforms, staff wear or resale programmes
• Sports Teams and Clubs — ear muffs & eye masks 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 ear muffs & eye masks 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 50 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.

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 GOTS, and we support REACH, CPSIA and Prop 65 declarations for the relevant markets.

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 3 days each.

Start your ear muffs & eye masks programme

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