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Manufacturing · Services · Design support

Design Support for Custom Headwear

Not every brand has a designer or a tech pack, and Mr Balaclava does not expect one. Our in-house design team turns a sketch, a reference product or a written brief into a digital mockup in 1–3 business days and a production-ready tech pack in 3–5, advises on fabrics, fit and branding, and prepares the sample. Design support is part of development for orders from 50 pieces per design, and the files we create belong to you.

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Updated

Design team around a table with drawings, colour swatch fans, pencils and a laptop
  • 50 pcsMinimum per design
  • 14 daysStandard lead time
  • 100K pcsMonthly capacity
  • 3–6 daysShipping (DHL, FedEx, UPS)
  • ISO 9001Certified (Eco Jersey Limited)

What we do

What design support covers

TaskWhat you getTime
Brief reviewA call or email to settle the product, the use, the market, the sizes and the target price before drawing startsWithin 1 business day
Digital mockupFlat drawings in your colours with logo and label placements; colourway variants on request1–3 business days
Fabric and trim adviceSuggested fabrics with swatches, trims and finishes that suit the use and the price pointWith the quote
Tech packMeasurements per size, materials, construction, branding files and packing instructions, editable3–5 business days
Logo preparationVector redraw of a raster logo, digitising for embroidery, colour separation for printingIncluded
Sample coordinationSample made on production machines; revisions written back into the tech pack5–7 days per sample
Range planningAdvice on which styles, colours and sizes to launch first for a category, based on what sells for similar brandsOn request

Starting points

Three ways a design usually begins

  • A reference product. A competitor's or your own earlier product, with notes on what to keep and what to change. The most common and the fastest start.
  • A sketch or a mood board. Even a hand drawing with a few measurements and the fabric you have in mind. We draw the flats and propose the construction.
  • A stock style to adapt. A style from the B2B Collection with your colours, branding and small changes; no tech pack from you is needed.

What the mockup and the tech pack contain

Designer working on a laptop with a drawing tablet at a wooden desk

Decisions we help with

The choices that decide whether a headwear product works

  • Fabric for the use

    Lycra, fleece, merino or knit, by climate, activity and price point, with organic and recycled options.

    Fabrics and yarns

  • Fit and sizing

    One size or a range, helmet compatibility, kids' sizes, the measurement table and its tolerances.

    Sizing and fit

  • Branding that lasts

    Which technique suits the fabric and the logo, where to place it, and how it will look after washing.

    Customization and branding

  • Cost drivers

    Which details move the unit price, and which alternatives give the same look at a lower cost.

    Order sizes and price tiers

How it works

Design support in five steps

  1. Brief

    Send what you have: sketches, references, logo, quantities, markets and deadline.

  2. Call or email review

    A designer confirms the product, the use and the open questions before drawing.

  3. Mockup rounds

    Drawings in 1–3 business days; revisions until the look is right.

  4. Tech pack

    The full specification in 3–5 business days, signed off by you.

  5. Sample and production

    Sample in 5–7 days; after approval, 14 days of production as standard.

Send a brief See the manufacturing process

Ownership and cost

What to expect

Your files
Mockups, tech packs and logo files developed for you are yours, delivered as PDF and editable files.
Confidential
Designs are not shown to or produced for other customers; NDAs on request.
Cost
Design support is part of development for an order. Samples are quoted separately and require 100% payment in advance.

FAQ

Design support: frequently asked questions

I have an idea but no drawings. Can you still make it?

Yes. Describe the product, send a reference photo or a rough sketch and your logo, and our designers create the mockup and the tech pack with you before the sample is made.

Does design support cost extra?

Mockups, tech packs and logo preparation are part of the development we do for an order from 50 pieces. Physical samples are quoted separately and require 100% payment in advance.

Who owns the design afterwards?

You do. The mockup, the tech pack and the logo files developed for your order are delivered to you and are not reused for other customers.

Can you improve a product I already sell?

Yes. Send the product and your customers' feedback; we propose changes to fabric, fit or construction on a new mockup and sample, and keep the rest as it is.

How many revisions are included?

Mockup revisions continue until the look is right; they are digital and quick. Sample revisions are made when a change affects construction, and each extra sample is quoted.

Do you help with the whole range, not just one product?

Yes. On request we advise which styles, colours and sizes to launch first in a category, based on what sells for similar brands, so the first order tests the right things.

More answers in our general FAQ

Buyer guides

Further reading

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