Manufacturing · Process · Customization and branding
Customization and Branding Options
Every product Mr Balaclava makes leaves the factory under your label. This page lists what you can decide: fabric, colour, fit, construction and trims, then the branding techniques we apply in-house (flat and 3D puff embroidery, screen printing, heat transfer, sublimation, woven and printed labels, patches and hang tags) and the packaging the piece ships in. All options are available from 50 pieces per design and previewed on the mockup and the sample before production.
Updated
- 50 pcsMinimum per design
- 14 daysStandard lead time
- 100K pcsMonthly capacity
- 3–6 daysShipping (DHL, FedEx, UPS)
- ISO 9001Certified (Eco Jersey Limited)
What you decide
The product side: what can be customised
These are the fields of the tech pack, in the order we settle them with you.
| Element | Your options | Notes |
|---|---|---|
| Fabric and yarn | Cotton, fleece, polyester and Lycra, merino, acrylic, bamboo; weight, finish, organic or recycled versions | Fabrics and yarns |
| Colour | Pantone-matched solids, yarn-dyed stripes and melange, all-over sublimation, tie-dye and dip-dye effects | Lab dips approved before bulk dyeing |
| Fit and sizes | One size, standard ranges or your own measurement table; kids' and extended sizes | Sizing and fit |
| Construction | Face openings (one, two or three holes), mesh panels, linings, ear and ponytail openings, cuffs, brims, drawcords, zips, thumb holes | Confirmed on the mockup; seam types chosen for the fabric |
| Trims | Pom-poms, toggles, elastic, reflective piping, silicone grippers, zip pullers | Supplier references listed in the tech pack |
| Labels | Woven or printed neck labels, size labels, care labels in the languages of your markets, hem tags | Or blank labels for white label orders |
| Packaging | Polybag, kraft paper wrap, recycled kraft box, hang tag, barcode and insert card, retail or bulk packing | Packing and shipping |
Branding techniques
Which technique for which logo
The technique follows the fabric and the artwork. This table is how we choose; the mockup shows the result before you commit.
| Technique | Works on | Best for | Limits |
|---|---|---|---|
| Flat embroidery | Knits, fleece, cotton, caps, Lycra with backing | Logos and wordmarks up to about 12 cm; premium, durable look | Very fine text and gradients; adds stiffness on thin fabrics |
| 3D puff embroidery | Caps, beanies, fleece | Bold letters and shapes that stand off the surface | Not for fine detail or small logos |
| Screen printing | Cotton, cotton blends, bandanas, caps | Spot-colour graphics, large prints, promotional runs | One screen per colour; not for stretchy Lycra |
| Heat transfer | Cotton, fleece, polyester, blends | Multi-colour logos, small runs, reflective and metallic finishes, inside neck prints | Sits on the surface; less breathable over large areas |
| Sublimation | Polyester and polyester-Lycra only | All-over prints, gradients, photographic designs, camo | Not on cotton or wool; white or light base fabric |
| Knitted-in patterns | Knit beanies, balaclavas, scarves, socks | Jacquard logos, stripes, patterns that are part of the fabric | Resolution limited by the stitch; programmed before the sample |
| Labels and patches | Any product | Woven damask labels, satin and cotton labels, PVC, rubber, leather and woven patches, embossed logos | Placement confirmed on the mockup |
Embroidery
The most requested finish, done in-house
Logo embroidery is what most headwear brands ask for first. Our multi-head embroidery machines run the design from a digitised file, with thread colours matched to your Pantone references and the placement fixed by a template, so every piece in the run matches the approved sample.
- Digitising included. Send a vector logo; we convert it to a stitch file and show you a stitch-out on the sample.
- Placements: front, side, back, cuff, under-brim, inside neck; discreet or bold.
- On stretch fabrics such as Lycra balaclavas we use backing and adjusted density so the logo does not pucker.
- Wash-tested: embroidery threads and stabilisers are chosen to survive repeated washing.
Labels, tags and packaging
Everything that carries your name
Labels and packaging are specified in the tech pack alongside the product, so they are produced on time and packed in the right order.
- Neck and hem labels: woven damask, satin or printed cotton, with your logo, size and care text in the languages your markets require.
- Hang tags and inserts: printed cards with barcode, QR code and care instructions; swing tags on kraft or coated board.
- Packaging: clear or printed polybags, recyclable kraft paper wraps, recycled kraft boxes, tissue paper; retail-ready or bulk packing.
- Marketplace-ready: barcodes, size stickers and carton labels to the requirements of your retailer or marketplace.
How it works
From logo file to branded product
-
Send the artwork
A vector logo (AI, EPS, SVG or PDF) and your Pantone references. Photos and low-resolution files are redrawn by our team.
-
Mockup with placements
The logo is placed on the drawing at real size, with the technique we recommend for the fabric.
-
Sample with branding
The physical sample carries the real embroidery or print, so you judge colour, size and feel, not a render.
-
Production and inspection
Branding is applied inline and checked on every piece for position, colour and finish before packing.
Proof
Branding techniques on real orders
Streetwear BalaclavaWindproof Embroidery Balaclava ProjectView project 
Printed BalaclavaFingerprint Graphic Printed Balaclava ProjectView project 
Pure Cotton Screen Printing Bandana100% Cotton Screen Printing Bandana ProjectView project 
Sublimation Animal Face MaskSublimation Animal Face Mask ProjectView project - Denim Patch Printing BalaclavaDenim Patch Printing Balaclava ProjectView project
FAQ
Customization and branding: frequently asked questions
Which parts of the product can I customise?
All of them: fabric, colour, fit and sizes, construction details, trims, labels, branding and packaging. The tech pack records each decision, and the mockup and sample show them before production.
Is branding included in the price?
Your quote is per piece and includes the branding techniques specified in the tech pack. Digitising your logo for embroidery is included; extra placements, techniques or packaging are quoted as options so you can compare.
Can I see my logo on the product before ordering?
Yes, twice: on the digital mockup at real size and on the physical sample with the real embroidery or print.
What file do you need for my logo?
A vector file (AI, EPS, SVG or PDF) and the Pantone references of your colours. If you only have a JPEG or PNG, our design team redraws it as a vector.
Will the embroidery or print survive washing?
Yes. Threads, inks and transfers are chosen for the fabric and wash-tested on the sample. Care labels state the washing instructions for the finished product.
Can I order blank, unbranded products?
Yes. White label orders ship with blank labels or your labels only and no Mr Balaclava branding. Stock styles from the B2B Collection can be ordered blank from 50 pieces.
Buyer guides
Further reading
Manufacturing & ProductionEmbroidered Beanies: Stylish Winter Headwear with Custom DetailEmbroidered beanies combine warmth, comfort, and detailed stitching to create timeless winter accessories ideal for everyday wear.Read the guide 
Private Label & OEMLogo Beanies: Where Branding Meets Comfort and StyleLogo beanies blend comfort, style, and branding, making them perfect for everyday wear, street fashion, and promotional use.Read the guide 
Private Label & OEM · 4 min readPrivate Label Motorcycle Balaclava: How Brands Can Create ItLearn how a private label motorcycle balaclava helps brands build custom headwear. Explore materials, branding options, FAQ for your own line.Read the guide