Custom Bowler & Deby Hat in Tencel Lyocell with Ultrasonic Welding for Retail Chains

Custom Bowler & Deby Hat — Tencel Lyocell with Ultrasonic Welding

We build bowler & deby hat programmes from a tech pack or a physical reference sample. This Tencel Lyocell 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: suppliers who disappear once the deposit is paid, 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

• DTF Film Printing — available on Tencel Lyocell, quoted per position and per colour.
• Chain Stitch Embroidery — available on Tencel Lyocell, quoted per position and per colour.
• Custom Zip Puller — available on Tencel Lyocell, quoted per position and per colour.
• Glow-in-the-Dark Printing — available on Tencel Lyocell, quoted per position and per colour.
• Hangtag and Packaging — available on Tencel Lyocell, quoted per position and per colour.
• Foil Printing — available on Tencel Lyocell, quoted per position and per colour.
• Piece Dyeing — available on Tencel Lyocell, 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 Tencel Lyocell-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

• Spas and Salons — bowler & deby hat uniforms, staff wear or resale programmes
• Agriculture and Farming — bowler & deby hat uniforms, staff wear or resale programmes
• Chemical and Oil & Gas — bowler & deby hat uniforms, staff wear or resale programmes
• Airlines and Cruise Lines — bowler & deby hat uniforms, staff wear or resale programmes
• Airsoft and Paintball Clubs — bowler & deby hat 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 bowler & deby hat 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.

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.

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 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.

Start your bowler & deby hat programme

Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.