Case Study: Custom Press Stud for a Lingerie Specialist in Ireland
Source:Cabochon Gemstone Brooches /
Time:2026-09-18
Press Stud for a Lingerie Specialist in Ireland
A Lingerie Specialist approached us with a press stud requirement for the Ireland market. The brief was specific: a defined look, a hard launch date and a unit cost that had to survive freight and duty. This case study records what was specified, what went wrong in sampling and how the bulk order was delivered.
The challenge
- Cartons packed to the factory ratio instead of the buyer's size ratio
- A zipper puller that broke under pull test at the warehouse
- Reorders that quietly changed supplier and changed the hand feel
What we specified
| Item | Press Stud |
|---|---|
| Client type | A Lingerie Specialist |
| Market | Ireland |
| Order volume | 10,000 pieces across 2 specifications |
| Base material | TPU |
| Standard size | 32 mm Width |
| Finish | UV Printing |
| Sampling rounds | 2 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | ISO 9001 |
How it was resolved
- We rebuilt the specification around TPU and locked the tolerance before bulk.
- The finish was moved to Glossy Enamel Coating after strike-off tests showed better durability.
- A pre-production sample was approved and retained as the golden reference.
- Production ran with in-line inspection and a mid-run photo report.
- Cartons were packed to the client's own barcode and ratio specification.
Result
- 10,000 pieces delivered inside the 8-week window.
- Unit cost held within 2.0% of the original quotation.
- Inspection-related rejection stayed under 2.0%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Approve a pre-production sample made from the actual bulk base material. Substitute material behaves differently in finishing.
Planning something similar?
Share the programme details and we will propose two alternatives — one optimised for unit cost, one for lead time — and let you choose.
