Custom Tactical Helmet in Merino Wool with Seam Sealing for Boutique Brands

Custom Tactical Helmet — Merino Wool with Seam Sealing

We build tactical helmet 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, seam sealing 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 minimum order quantities far above what a growing brand can absorb. 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

• Hangtag and Packaging — available on Merino Wool, quoted per position and per colour.
• Custom Zip Puller — available on Merino Wool, quoted per position and per colour.
• Heat Transfer Printing — available on Merino Wool, quoted per position and per colour.
• All-Over Sublimation — available on Merino Wool, quoted per position and per colour.
• Seam Sealing — available on Merino Wool, quoted per position and per colour.
• DTG Digital Printing — available on Merino Wool, quoted per position and per colour.
• Chain Stitch Embroidery — 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 seam sealing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Bars and Nightclubs — tactical helmet uniforms, staff wear or resale programmes
• Veterinary Clinics — tactical helmet uniforms, staff wear or resale programmes
• Security Services — tactical helmet uniforms, staff wear or resale programmes
• Chemical and Oil & Gas — tactical helmet uniforms, staff wear or resale programmes
• E-commerce Private Label — tactical helmet 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 tactical helmet 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 14 working days after the tech pack is confirmed, including fabric sourcing if the base cloth is not in our stock library. Revisions add about 5 days each.

Do you provide compliance documents?

We can arrange OEKO-TEX, GOTS, BSCI, WRAP and ISO documentation as well as third-party testing reports for BSCI, and we support REACH, CPSIA and Prop 65 declarations for the relevant markets.

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.

Start your tactical helmet programme

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