Case Study
Project Overview
Mr Balaclava developed 100 Extended Balaclavas for riders with long hair and locs across the UK and European market.
The client needed extra room for longer hairstyles. Therefore, our team developed an extended shape instead of a standard profile.
We used a fabric with 95% Jersey and 5% Spandex. Additionally, the client selected a black shell.
The project included two stitching looks. One used gold contrast stitching, while the other used black tonal stitching.
Our team first developed a sample for approval. Afterward, we completed all 100 pieces within seven days on an express schedule, as requested by the client.
The Challenge
The main challenge involved creating comfortable extra space for riders with long hair and locs.
A standard balaclava lacked enough room. Therefore, our team focused on a longer construction.
Meanwhile, we maintained the wide eye opening and overall fit.
The stitching also required consistent placement across the extended panels and lower sections.
Our Solution
First, our team developed an extended pattern that created additional room for long hair and locs.
Next, we shaped the wide eye opening according to the approved design and maintained the requested one-size fit.
Then, our team prepared a sample for client review. The client approved the construction before bulk production.
During production, we followed both approved stitching options: gold contrast stitching and black tonal stitching.
Moreover, our QC team checked construction during production and completed a final inspection before packing.
Finally, we completed all 100 pieces within the requested seven-day express lead time.
Detailed Result
The final Extended Balaclava followed the approved sample and maintained the requested extended construction.
Its longer design created extra room for long hair and locs.
Meanwhile, the wide eye opening followed the approved shape.
Our team completed both stitching variations on the black shell, creating tonal and contrast visual options.
We completed all 100 pieces within seven days on an express schedule.
After inspection, our team packed the products for Air Express shipping.
