CASE STUDY · SWIMWEAR · NYC

How a Brooklyn swim founder launched a 4-piece line with 3 sample iterations and zero fit-correction reorders

Swim is the most fit-critical category. 1 in 3 indie swim brands has a sizing-correction reorder in Year 1. Here's how our Brooklyn founder avoided it.

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4
Styles launched
3
Fit iterations
0
Fit-correction reorders
£60k
Saved on remake risk
THE BRAND

A Brooklyn-based swim founder who refused to ship a bad fit

Ex-Solid & Striped pattern-maker turned founder. Knew swim fit better than most factory engineers. Refused to ship Drop 1 with anything less than 3 sample iterations.

Most first-time swim brands ship Drop 1 after 1 fit sample. 30-40% have a sizing-correction reorder within 6 months — that's £30-80k of lost money on remakes.

WHAT WE DID

Why 3 fit iterations matter for swim

Step 1

Iteration 1: Tech pack accuracy

Spec cup grade, gusset, lining. First sample close to spec — but body curve was off in size XS + L.

Step 2

Iteration 2: Curve correction

Re-graded across 5 sizes. Cup spec + side seam adjusted. Sample 2 fit 4 of 5 sizes well.

Step 3

Iteration 3: Final lock

Last tweak to XS underwire channel. All 5 sizes locked. PP sample approved.

Step 4

Bulk: 200 units × 4 styles

800 units total. 4-stage QC at our Shanghai swim-specialist line. Direct-to-Brooklyn 3PL.

WHAT THE FOUNDER SAID
"In swim, you don't get a second chance with the customer. A bad-fit one-piece is returned and reviewed badly. Fabrickly was the only factory that built 3 iterations into the project from Day 1."
— Founder, Brooklyn swim DTC
THE OUTCOME

0 fit-correction reorders. £60k saved vs industry norm.

Drop 1 sold through with 4.7-star average review, 1.2% size-related return rate (industry average: 8-15%). Reorder placed at 350 units per style.

Industry norm: 30-40% of first-time swim brands have a sizing-correction reorder, costing £30-80k. Ours: zero. The 3-iteration investment paid for itself many times over.

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WHAT WORKED

Why this brand succeeded

Custom-tier upfront

Pro tier includes 4 revisions. Founder used 3, saved the 4th. Right call for fit-critical category.

Swim-specialist factory

Shanghai line specializes in bonded seams, lined construction, hook-eye spec. Generalist factories make swim badly.

Sized the iterations correctly

3 fit samples × 5 sizes = 15 samples tested before bulk. £450 cost. Saved £60k+ in remake risk.

Swim brand? Don't skip fit iterations.

Bonded seams. Lined gussets. 3 sample iterations included on Custom tier.

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