Custom Theatrical Costume in Selvedge Denim with Ultrasonic Welding for Retail Chains

Custom Theatrical Costume — Selvedge Denim with Ultrasonic Welding

We build theatrical costume programmes from a tech pack or a physical reference sample. This Selvedge Denim 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: no reliable way to track a order once it enters production, 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

• Piece Dyeing — available on Selvedge Denim, quoted per position and per colour.
• Chenille Embroidery — available on Selvedge Denim, quoted per position and per colour.
• Bonding Construction — available on Selvedge Denim, quoted per position and per colour.
• Foil Printing — available on Selvedge Denim, quoted per position and per colour.
• Seam Sealing — available on Selvedge Denim, quoted per position and per colour.
• Distressed Finish — available on Selvedge Denim, quoted per position and per colour.
• Reflective Printing — available on Selvedge Denim, 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 Selvedge Denim-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

• Mining Operations — theatrical costume uniforms, staff wear or resale programmes
• Real Estate Agencies — theatrical costume uniforms, staff wear or resale programmes
• E-commerce Private Label — theatrical costume uniforms, staff wear or resale programmes
• Wholesale and Distribution — theatrical costume uniforms, staff wear or resale programmes
• Airlines and Cruise Lines — 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

How long does sampling take?

A first prototype is typically ready in 7 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.

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

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