Custom Ear Muffs & Eye Masks in Nylon with Ultrasonic Welding for Outdoor & Workwear Programs

Custom Ear Muffs & Eye Masks — Nylon with Ultrasonic Welding

We build ear muffs & eye masks programmes from a tech pack or a physical reference sample. This Nylon 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: 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

• Foil Printing — available on Nylon, quoted per position and per colour.
• Sequin Work — available on Nylon, quoted per position and per colour.
• Hangtag and Packaging — available on Nylon, quoted per position and per colour.
• Garment Dyeing — available on Nylon, quoted per position and per colour.
• Chenille Embroidery — available on Nylon, quoted per position and per colour.
• Rhinestone Application — available on Nylon, quoted per position and per colour.
• Padding and Wadding — available on Nylon, 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 Nylon-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

• Tennis Academies — ear muffs & eye masks uniforms, staff wear or resale programmes
• Airsoft and Paintball Clubs — ear muffs & eye masks uniforms, staff wear or resale programmes
• Pet Care and Grooming — ear muffs & eye masks uniforms, staff wear or resale programmes
• Laboratories and Pharma — ear muffs & eye masks uniforms, staff wear or resale programmes
• Workwear and Industrial — 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 100 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 14 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.

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 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 ear muffs & eye masks 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.