Custom Hat Bucket — Chambray with Padding and Wadding
We build hat bucket programmes from a tech pack or a physical reference sample. This Chambray 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, padding and wadding 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: minimum order quantities far above what a growing brand can absorb, 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
| Product | Hat Bucket |
|---|---|
| Base fabric | Chambray |
| Decoration / finish | Padding and Wadding |
| Fabric weight | 280-320 gsm |
| Size range | 0-24M baby |
| Colour options | 16 Pantone-matched shades |
| MOQ | 100 pieces per style per colour |
| Sampling | 12 working days, 3 days per revision |
| Bulk lead time | 30-35 days after approval |
| Compliance | OEKO-TEX Standard 100 |
What you can customise
- Ruching — available on Chambray, quoted per position and per colour.
- Custom Button — available on Chambray, quoted per position and per colour.
- Foil Printing — available on Chambray, quoted per position and per colour.
- Woven Label — available on Chambray, quoted per position and per colour.
- Acid Wash — available on Chambray, quoted per position and per colour.
- Yarn Dyeing — available on Chambray, quoted per position and per colour.
- Distressed Finish — available on Chambray, quoted per position and per colour.
How we produce it
- Tech pack review and fabric confirmation
- Lab dips or print strike-off for approval
- Pattern making, grading and a Chambray-spec prototype
- Fit sample and wearer test, then a pre-production sample
- Bulk cutting with padding and wadding applied under controlled settings
- In-line inspection, final AQL 2.5 inspection and packing
Typical applications
- Automotive Dealerships — hat bucket uniforms, staff wear or resale programmes
- Wholesale and Distribution — hat bucket uniforms, staff wear or resale programmes
- Airlines and Cruise Lines — hat bucket uniforms, staff wear or resale programmes
- Running and Marathon Events — hat bucket uniforms, staff wear or resale programmes
- Kidswear Subscription Boxes — hat bucket 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 hat bucket batches stay comparable over time. Inspection photos and the measurement report are sent before the balance payment is due.
FAQ
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 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.
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.
Start your hat bucket programme
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
