01
Silhouette
Boxy or oversized shapes balance room for loft and layering; tailored or athletic shapes use articulated sleeves and narrower channels; longline and convertible concepts change coverage and component needs.
Outerwear · insulated construction
Build the puffer around its baffle
Shell, lining, fill, channel design and seam detail work together. Define them as one product system, then review the physical sample before confirming a bulk specification.
Construction sequence
01
Shell
02
Channel
03
Fill
04
Closure
Review each element against the garment's approved BOM and sample.
Shell and insulation options
Choose a material direction, then verify it
Denier, weight and fill ranges are specification examples. They do not certify performance of an untested product.
| Component | Illustrative specification | Development check |
|---|---|---|
| Nylon ripstop shell | 20D–40D; 35–65 GSM | Light shell construction option; confirm composition, finish and test criteria. |
| Polyester taffeta | 50D–75D; 70–110 GSM | Smooth shell option; recycled content and any finish require order documentation. |
| Taslan nylon | 100D–160D; 130–180 GSM | More structured shell direction; confirm coating and intended use. |
| Synthetic micro-denier fill | 100–350 GSM | Sheet or blowable fill option; agree material identity, allocation and sample criteria. |
| Natural down | 550–800+ fill power shown as an example | Specify the selected fill and request current product and transaction documentation before stating any certification or performance. |
Construction decisions
Translate the silhouette into a build sheet
02
Baffle
Sewn-through horizontal or vertical channels are one construction option. Box-wall baffles add a separating wall; select the construction for the product brief and test the approved sample.
03
Needle and thread
Ballpoint needles in sizes 65/9 to 75/11 and core-spun polyester thread are listed for review. Confirm suitability against the selected shell, lining and seam sample.
04
Seam details
A 10–12 SPI reference is listed alongside seam tape, storm plackets, bar-tacks, hem shock cord, toggles and adjustable cuffs. Set acceptance criteria on the tech pack.
Construction details include TPU seam tape at selected seams, storm plackets, bar-tacks, shock-cord hem adjustment, branded hardware, embroidery or transfer decoration, labels and compression packaging. Add only the details needed for the design and confirm them on the sample.
Sampling and production
Approve the physical reference
- 01
Tech pack
Record silhouette, POMs, BOM, baffle layout, shell, lining, fill and trim.
- 02
First prototype
Review shoulder pitch, armhole clearance, loft, baffle distribution and overall shape.
- 03
Pre-production sample
Check the selected bulk materials, dye, fill allocation and decoration; sign off before production.
- 04
Final inspection
Agree lot sampling, dimensional checks and any fill, leakage, zipper or weather-related test criteria.
Order planning references
- MOQ
- 50 pieces per style as a planning reference
- Sampling
- 10–15 production days + 3–5 shipping days
- Bulk
- 15–20 days after PP sample sign-off
- Shipping
- DAP courier; FOB at the designated export port
Planning references only. Confirm feasibility, order-specific terms and delivery scope before scheduling.
Questions
Puffer development and inspection
Which shell weights are shown as examples?
Illustrative shell options include nylon ripstop at 20D–40D and 35–65 GSM, polyester taffeta at 50D–75D and 70–110 GSM, and Taslan nylon at 100D–160D and 130–180 GSM. Treat these as material directions to validate.
Can you guarantee warmth or water resistance?
No. Insulation performance, down leakage, water resistance and seam sealing require a chosen material, test method, sample and written acceptance criteria.
What are the construction references?
Construction references include sewn-through and box-wall baffles, 65/9–75/11 ballpoint needles, core-spun polyester thread and 10–12 SPI. Confirm construction suitability and tolerances for the approved sample.
What are the planning references?
Planning references are 50 pieces per style, 10–15 days for sampling plus 3–5 days shipping, and 15–20 days for bulk after PP sign-off. Confirm timing, material availability and delivery terms per order.
How should inspection be agreed?
ANSI/ASQ Z1.4 Level II and AQL 2.5 are planning references. Set the inspection plan and define how fill, measurements, seams, trims and any performance tests will be evaluated.
Outerwear project brief
Review the shell, fill and construction together
Share the silhouette, material direction, baffle plan, target measurements, quantity and required test evidence.
Discuss a puffer project