Custom Boonie in Flannel with Ultrasonic Welding for Outdoor & Workwear Programs

Custom Boonie — Flannel with Ultrasonic Welding

We build boonie programmes from a tech pack or a physical reference sample. This Flannel 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 color drift between lab dips and bulk fabric. 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

• Tie-Dye Wash — available on Flannel, quoted per position and per colour.
• Chenille Embroidery — available on Flannel, quoted per position and per colour.
• Piece Dyeing — available on Flannel, quoted per position and per colour.
• Custom Zip Puller — available on Flannel, quoted per position and per colour.
• Tonal Embroidery — available on Flannel, quoted per position and per colour.
• Shirring — available on Flannel, quoted per position and per colour.
• Screen Printing — available on Flannel, 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 Flannel-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

• Gyms and Fitness Studios — boonie uniforms, staff wear or resale programmes
• Yoga and Pilates Studios — boonie uniforms, staff wear or resale programmes
• Retail Store Staff — boonie uniforms, staff wear or resale programmes
• Scouts and Youth Clubs — boonie uniforms, staff wear or resale programmes
• Dental and Veterinary Clinics — boonie 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 boonie batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.

FAQ

Do you provide compliance documents?

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

What is the minimum order quantity?

Standard programmes start at 150 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 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.

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 boonie 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.