Custom Theatrical Costume in Merino Wool with Garment Dyeing for Boutique Brands

Custom Theatrical Costume — Merino Wool with Garment Dyeing

We build theatrical costume programmes from a tech pack or a physical reference sample. This Merino Wool 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, garment dyeing 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: minimum order quantities far above what a growing brand can absorb, or color drift between lab dips and bulk fabric. 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

• Quilting — available on Merino Wool, quoted per position and per colour.
• Ruching — available on Merino Wool, quoted per position and per colour.
• Yarn Dyeing — available on Merino Wool, quoted per position and per colour.
• Shirring — available on Merino Wool, quoted per position and per colour.
• Custom Zip Puller — available on Merino Wool, quoted per position and per colour.
• Snow Wash — available on Merino Wool, quoted per position and per colour.
• Embossing — available on Merino Wool, 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 Merino Wool-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with garment dyeing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Airsoft and Paintball Clubs — theatrical costume uniforms, staff wear or resale programmes
• Manufacturing Plants — theatrical costume uniforms, staff wear or resale programmes
• Restaurants and Cafes — theatrical costume uniforms, staff wear or resale programmes
• Cleaning and Janitorial — theatrical costume uniforms, staff wear or resale programmes
• Construction Sites — theatrical costume 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 theatrical costume 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 200 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.

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.

Start your theatrical costume programme

Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.