Custom Boonie in Rayon with Placement Printing for Sportswear Brands

Custom Boonie — Rayon with Placement Printing

We build boonie programmes from a tech pack or a physical reference sample. This Rayon 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, placement printing 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: packaging that arrives crushed and unsellable, 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

• Enzyme Wash — available on Rayon, quoted per position and per colour.
• Placement Printing — available on Rayon, quoted per position and per colour.
• Flocking — available on Rayon, quoted per position and per colour.
• Piping and Binding — available on Rayon, quoted per position and per colour.
• Applique Embroidery — available on Rayon, quoted per position and per colour.
• Rhinestone Application — available on Rayon, quoted per position and per colour.
• Care Label — available on Rayon, 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 Rayon-spec prototype
4. Fit sample and wearer test, then a pre-production sample
5. Bulk cutting with placement printing applied under controlled settings
6. In-line inspection, final AQL 2.5 inspection and packing

Typical applications

• Universities — boonie uniforms, staff wear or resale programmes
• Corporate Merch Programs — boonie uniforms, staff wear or resale programmes
• Airsoft and Paintball Clubs — boonie uniforms, staff wear or resale programmes
• Bars and Nightclubs — boonie uniforms, staff wear or resale programmes
• Music Bands and Touring — 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

What is the minimum order quantity?

Standard programmes start at 50 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 OEKO-TEX Standard 100, and we support REACH, CPSIA and Prop 65 declarations for the relevant markets.

How long does sampling take?

A first prototype is typically ready in 7 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.

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.

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.