Custom Baseball Cap in Rib Knit with Ultrasonic Welding for Sportswear Brands

Custom Baseball Cap — Rib Knit with Ultrasonic Welding

We build baseball cap programmes from a tech pack or a physical reference sample. This Rib Knit 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 packaging that arrives crushed and unsellable. 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

• Sequin Work — available on Rib Knit, quoted per position and per colour.
• Reflective Printing — available on Rib Knit, quoted per position and per colour.
• Pantone Color Matching — available on Rib Knit, quoted per position and per colour.
• Bonding Construction — available on Rib Knit, quoted per position and per colour.
• Piece Dyeing — available on Rib Knit, quoted per position and per colour.
• Yarn Dyeing — available on Rib Knit, quoted per position and per colour.
• Contrast Stitching — available on Rib Knit, 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 Rib Knit-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

• Surf and Swim Brands — baseball cap uniforms, staff wear or resale programmes
• Corporate Merch Programs — baseball cap uniforms, staff wear or resale programmes
• Veterinary Clinics — baseball cap uniforms, staff wear or resale programmes
• Aviation and Airlines — baseball cap uniforms, staff wear or resale programmes
• Government and Municipal — baseball cap 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 baseball cap batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

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.

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.

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.

Do you provide compliance documents?

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

Start your baseball cap programme

Send us your tech pack or even a rough sketch — we will come back with fabric options, a costed sample plan and a realistic production calendar.