Custom Other Sports Cap in Seersucker with Ultrasonic Welding for Boutique Brands

Custom Other Sports Cap — Seersucker with Ultrasonic Welding

We build other sports cap programmes from a tech pack or a physical reference sample. This Seersucker 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: long lead times that miss the selling season, 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

• Smocking — available on Seersucker, quoted per position and per colour.
• Embossing — available on Seersucker, quoted per position and per colour.
• Puff Printing — available on Seersucker, quoted per position and per colour.
• Seam Sealing — available on Seersucker, quoted per position and per colour.
• 3D Puff Embroidery — available on Seersucker, quoted per position and per colour.
• Tonal Embroidery — available on Seersucker, quoted per position and per colour.
• Custom Button — available on Seersucker, 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 Seersucker-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

• Maternity and Baby Care — other sports cap uniforms, staff wear or resale programmes
• Wedding and Bridal — other sports cap uniforms, staff wear or resale programmes
• E-commerce Private Label — other sports cap uniforms, staff wear or resale programmes
• Banking and Finance — other sports cap uniforms, staff wear or resale programmes
• Airsoft and Paintball Clubs — other sports 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 other sports cap batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

What is the minimum order quantity?

Standard programmes start at 500 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.

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.

How long does sampling take?

A first prototype is typically ready in 10 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.

Start your other sports cap programme

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