Case Study: Custom Woven Patch for a Lingerie Specialist in Australia
Source:Synthetic Hair Bulk /
Time:2026-09-18
Woven Patch for a Lingerie Specialist in Australia
A Lingerie Specialist approached us with a woven patch requirement for the Australia 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
- Elastic that lost recovery after three washes
- An interlining that bubbled after the first press
- Lead time quoted without the plating or dyeing sub-process
What we specified
| Item | Woven Patch |
|---|---|
| Client type | A Lingerie Specialist |
| Market | Australia |
| Order volume | 20,000 pieces across 2 specifications |
| Base material | Nylon |
| Standard size | 9 mm Width |
| Finish | Chrome Plating |
| Sampling rounds | 4 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | Sedex SMETA |
How it was resolved
- We rebuilt the specification around Nylon and locked the tolerance before bulk.
- The finish was moved to Mercerised Finish 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
- 20,000 pieces delivered inside the 6-week window.
- Unit cost held within 3.0% 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
Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.
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.
