Refining a Proven Denim Design for a Larger Repeat Order
The initial run of 100 denim shorts gave the client an opportunity to evaluate the product under real-world conditions. When the time came to scale the design, the goal was not simply to reproduce the original version.
For the new production run, we sourced a denser stretch denim weighing 402 GSM and made from 98% cotton and 2% spandex.
The fabric underwent shrinkage testing before bulk production to assess its performance after washing. The results confirmed that the new material offered greater stability while supporting the close-fitting silhouette.
During sample development, our team also:
refined the size range;
reviewed garment length and overall proportions;
replaced the original eyelets with brown hardware at the client’s request;
improved eyelet alignment and symmetry;
developed samples in multiple sizes;
completed an internal quality review before shipment.
The updated samples allowed the client to assess the fabric, fit, hardware, and overall execution before committing to the larger order.
Once the core construction had been approved, the client expanded the concept by adding navy side lacing threaded through the eyelets.
The required tape was not available as a standard trim, so it was sourced specifically for the project. An additional sample was developed to evaluate the lacing density, eyelet placement, symmetry, and overall balance of the new detail.
We also tested a decorative patch option. When the available patches showed signs of distortion after washing, Fashion Atlas recommended removing them from the production specification. This prevented an unreliable detail from being repeated across 500 finished garments.
The final production process included:
a specialized denim wash treatment;
eyelet installation after washing;
spacing and symmetry checks;
hand-threading of the navy lacing;
final pressing, inspection, and packing.
The client received more than a larger run of the original design. The result was a more refined and technically reliable version of the product.
Fashion Atlas managed the fabric sourcing, sample development, wash testing, technical refinements, and manual application of the decorative elements. This eliminated the need for the client to finish or modify the garments after delivery and created a complete, retail-ready product.
The original 100-unit run developed into a repeat order for 500 denim shorts — now produced with a more stable fabric, refined construction, and a stronger signature detail.
Tested in the market. Refined before production. Scaled with confidence.
