Custom Theatrical Costume in Tencel Cotton Blend with 3D Puff Embroidery for Retail Chains

Custom Theatrical Costume — Tencel Cotton Blend with 3D Puff Embroidery

We build theatrical costume programmes from a tech pack or a physical reference sample. This Tencel Cotton Blend 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, 3d puff embroidery 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 unclear responsibility when a defect shows up after washing. 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

• Puff Printing — available on Tencel Cotton Blend, quoted per position and per colour.
• Bonding Construction — available on Tencel Cotton Blend, quoted per position and per colour.
• Flat Embroidery — available on Tencel Cotton Blend, quoted per position and per colour.
• Piping and Binding — available on Tencel Cotton Blend, quoted per position and per colour.
• Piece Dyeing — available on Tencel Cotton Blend, quoted per position and per colour.
• Ultrasonic Welding — available on Tencel Cotton Blend, quoted per position and per colour.
• Contrast Stitching — available on Tencel Cotton Blend, 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 Cotton Blend-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with 3d puff embroidery applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Workwear and Industrial — theatrical costume uniforms, staff wear or resale programmes
• Electronics Assembly — theatrical costume uniforms, staff wear or resale programmes
• Food Processing — theatrical costume uniforms, staff wear or resale programmes
• Retail Store Staff — 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 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.

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.

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.

Start your theatrical costume programme

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