Scaling a boutique
yoga label
into 12 markets.
A US-based DTC yoga brand approached us in Q1 2024 to re-engineer their signature high-waist legging line — targeting a 3x volume increase while raising fabric performance and streamlining unit cost.
What the brand
needed from us.
Detailed briefing across performance, aesthetics and supply chain — translated into engineering specs.
Squat-Proof Compression
High-density interlock knit with 4-way stretch, opacity above 92%, holding shape through 200+ wash cycles.
Sculpting Silhouette
Butt-lift contour paneling, 5" waistband with hidden pocket, seamless gusset for 360° movement.
Recycled Nylon Base
GRS-certified recycled nylon blended with spandex, OEKO-TEX STANDARD 100, PFAS-free finish.
Signature Detailing
Debossed silicone logo on waistband, custom pantone colorways, branded eco-friendly polybags.
45-Day Full Cycle
Sample-to-shipment within 45 days including salesman sample confirmation and PP sample sign-off.
Scalable Volume
Trial batch 500 pcs, first bulk order 15,000 pcs, expansion capacity up to 100,000 pcs per drop.
Engineering the
perfect stretch.
Our fabric lab curated 6 candidate knits and iterated 4 pattern blocks before locking the final combination — validated by wear-testers across 5 body types.
75D Recycled Nylon / 25D Spandex — Buttery Interlock
240 gsm double-knit interlock delivers matte finish, sculpting compression and cloud-soft handfeel. Passed 40 wash-cycle colorfastness at grade 4+.
Contour Curve Paneling
6-panel construction with center-back V-seam creates a lifted silhouette. Diamond gusset eliminates crotch stress in deep squats.
- ✦ High-rise 5" waistband, no roll-down
- ✦ Hidden waistband key pocket
- ✦ Flatlock stitching, chafe-free
- ✦ Graded XXS–3XL, 8 sizes
From tech-pack
to signed sample.
A 4-stage sampling workflow, each stage sealed with client sign-off before moving forward.
Proto Sample
First 3D fit sample cut from stock fabric to validate proportions and construction logic. Reviewed via video-fitting.
Fit Sample
Custom-dyed pantone fabric applied. Size run XS/M/XL sampled for graded fit validation on live models.
Salesman Sample
Fully branded sample with debossed silicone logo, care labels, hangtags and eco-polybag — ready for showroom & lookbook.
PP Sample (Sealed)
Pre-production sample cut from bulk fabric on the same production line — sealed as golden reference for QC benchmarking.
85,000 units.
17 days.
Dedicated production line, CNC auto-cutting, and multi-stage QC pipeline delivered bulk on-schedule with zero major defects.
CNC Auto Cutting
6-layer spread with ±0.5mm precision. Zero manual re-cut, 8% fabric-waste reduction.
Flatlock Sewing Line
32 skilled operators on dedicated 4-thread flatlock and coverstitch machines.
Inline QC (AQL 2.5)
Real-time inline inspection every 500 pcs, plus final full-inspection before packing.
Packing & Shipment
Branded eco-polybag, master carton labeling, FOB Shenzhen with sea + air split.
What the brand
got in return.
Measurable business impact within the first 90 days after launch — enough to trigger a third reorder within one quarter.
First bulk drop sold through in under 30 days across Shopify + Amazon.
Versus previous supplier — driven by CNC cutting yield and fabric consolidation.
Down from 4.8% industry benchmark — driven by superior fit and fabric.
"Pro Sportswear turned around a full 14-SKU line in 45 days with a fit and hand-feel that outperformed our previous $80 legging. We've re-ordered three times in one quarter."
Within one quarter post-launch.
From 4 initial regions to 12 countries across NA & EU.
Similar project
in mind?
Send us your tech pack, moodboard or a rough idea. We'll respond within 12 hours with a feasibility outline & indicative quote.
- ✦ Free tech-pack review & fabric recommendation
- ✦ Sample from 50 pcs, bulk from 500 pcs
- ✦ Full IP protection & NDA on request
- ✦ International certifications included
Request a Case-Match Quote
Tell us about your project — we'll match it to a similar case and reply with a tailored plan.