Custom Theatrical Costume in Slub Cotton with Ultrasonic Welding for Retail Chains

Custom Theatrical Costume — Slub Cotton with Ultrasonic Welding

We build theatrical costume programmes from a tech pack or a physical reference sample. This Slub Cotton 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: unclear responsibility when a defect shows up after washing, or no reliable way to track a order once it enters production. 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

• Ribbed Cuff and Hem — available on Slub Cotton, quoted per position and per colour.
• Rhinestone Application — available on Slub Cotton, quoted per position and per colour.
• Shirring — available on Slub Cotton, quoted per position and per colour.
• Snow Wash — available on Slub Cotton, quoted per position and per colour.
• Yarn Dyeing — available on Slub Cotton, quoted per position and per colour.
• Placement Printing — available on Slub Cotton, quoted per position and per colour.
• Laser Cutting — available on Slub Cotton, 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 Slub Cotton-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

• Laboratories and Pharma — theatrical costume uniforms, staff wear or resale programmes
• Airlines and Cruise Lines — theatrical costume uniforms, staff wear or resale programmes
• Music Bands and Touring — theatrical costume uniforms, staff wear or resale programmes
• Bars and Nightclubs — theatrical costume uniforms, staff wear or resale programmes
• Corporate Merch Programs — 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.

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.

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 3 days each.

Start your theatrical costume programme

Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.