OEM & Private Label · Cap Encyclopedia
Cap Sampling Timeline
Sampling is where most cap programmes lose time. Three stages — digital mock, PP sample, size run — each with a realistic lead time and a fabric-sourcing gate.
Digital mock
2–3 days
From tech pack
PP sample
10–15 days
Fabric-gated
Size run
7–10 days
Fitted programmes
Full cycle
3–4 weeks
Tech pack to approval
Stage 1 — Digital mock
- Timeline: 2–3 working days from a complete tech pack.
- Deliverable: flat or 3D render with all decoration positioned, Pantone-matched.
- Purpose: sign off on artwork, panel layout and closure before physical sampling starts.
- Cost: usually free with a signed NDA and confirmed sampling PO.
- Faster with: vector art files, Pantone TCX codes, and a reference cap image.
Stage 2 — PP (pre-production) sample
- Timeline: 10–15 working days after digital mock approval.
- Deliverable: physical cap in bulk fabric, with final decoration and trims.
- Purpose: sign off construction, fabric hand-feel, decoration quality and closure function.
- Cost: sample cost + courier. Usually credited against the first bulk PO.
- The gate: sourcing bulk fabric in the exact Pantone. Stock fabric colours cut 5–7 days.
- Approve or revise: request one revision only if a spec is wrong — chasing perfection at PP resets the clock.
Stage 3 — Size-run sample (fitted programmes)
- Only needed for fitted caps — one PP sample cannot validate an 8-size ladder.
- Timeline: 7–10 days after PP approval.
- Deliverable: one cap per size (typically 6 7/8, 7, 7 1/4, 7 1/2, 7 5/8).
- Purpose: confirm grading across the ladder — crown circumference, sweatband length and visor scale.
Where sampling loses days
- Incomplete tech pack — missing fibre content, Pantone or closure spec resets Stage 1.
- Custom-dyed fabric — mill dye lots add 10–15 days on top of PP sample.
- Late artwork revisions — every digitising change resets the embroidery step.
- Trim sourcing — a specific main-label supplier can add a full week.
- Air freight backups — courier customs holds add 2–4 days at destination.
Start your cap sampling schedule
Send your tech pack — we'll return a costed sampling plan with realistic milestones inside 48 hours.