Most delays in custom headwear come from approvals, not production. Understanding the sequence helps you plan launches and avoid air-freight surprises.
Week 1: brief and digital mock-up
Artwork, quantity, target price and delivery date are reviewed. A mock-up is issued for sign-off, usually within one business day.
Weeks 2–3: sampling
A pre-production sample is made in 7–10 days. Fit, colour and decoration are reviewed; revisions add 5–7 days per round.
Weeks 3–4: material preparation
Fabric, trim and labels are booked. Custom dyeing or woven labels can add 10–15 days if not ordered in advance.
Weeks 4–8: bulk production
Cutting, sewing, embroidery and finishing run in sequence. Typical bulk lead time is 20–35 days depending on quantity and decoration complexity.
Final week: inspection and shipping
AQL 2.5 inspection, packing and documentation take 3–5 days. Sea freight to Europe or the US typically adds 25–35 days; air freight 5–8 days.
Plan backwards from your in-hands date and add a buffer for approval delays. Sharing a complete tech pack at the start is the single biggest time saver.