Our interest in developing Alpha Direct began when one of our team members was introduced to the product by chance. The effectiveness of the product speaks for itself, and there's no need to elaborate further on its benefits.
In summary: Lightweight, breathable, and warm.
Especially when paired with a wool base layer, the Alpha mid-layer is a perfect match. Alpha Direct has completely replaced my synthetic insulation. (P.S. I’m not sensitive to the cold, but for those who are, it's still a good idea to carry extra down insulation in winter.)
For more information about the fabric, please visit Polartec official website：Click
How can we purchase the fabric?
Alpha Direct fabric is manufactured in the United States and can only be obtained by purchasing directly from Polartec or its distributors.
Currently, we do not have plans for large-scale production, so we procure off-cuts of fabric from the U.S., which are then shipped to Taiwan for production by selected garment factories.
Why not dye our own colors?
Firstly, the variety of colors in off-cuts is extensive, and secondly, it reduces the manufacturing time.
The downside is the limited quantity of fabric, which may result in some customers missing out. However, as the development process matures, the speed and variety of future releases will increase.
Even when purchasing off-cuts through official channels, you can still apply for the company’s logo label from Polartec. We have already submitted our application, but the process is lengthy and complex, so the labels will appear on future products.
Contract Manufacturer Development
One of our regular customers, Mr. Li, who is skilled in handmade fabric arts, casually discussed and initiated this development process. The Blue Neck Gaiter is a creation by Mr. Li. As the range of developed products expands and with the variation in processes and machinery, it is essential to partner with specialized factories.
Taiwan has many garment factories, but due to industry relocation and the aging of skilled workers, many have gradually declined, with some unable to handle large orders. However, the variety of machinery and the mature sewing techniques and experience they possess are well-suited to our needs.
Given this, we sought out garment factories in Changhua for nearby communication and sampling. Initially, Taiwanese garment factories were unfamiliar with Alpha Direct and were almost overwhelmed by the large holes in the fabric. XD They were completely unaware of the fabric’s popularity in the mountaineering community and were shocked when they learned the retail price. Some even had difficulty distinguishing between the front and back of the fabric.
Sewing Techniques
In addition to the already released neck gaiters and hooded tees, we have also used off-cuts to create samples for customer requests or products needed for our mountaineering trips. From some details, the experience of the garment factory’s skilled workers is evident.
Here are a few simple examples; colors are for reference only and are not indicative of future products:
The hooded zip-up tee is the most requested item. The YKK zipper is fully covered at the ends to prevent any friction against the face.
The pattern maker’s craftsmanship is exceptional, completing the hat’s shaping on the first try.
The reason the first generation hooded tee did not have edge binding is due to the weaving technology of Alpha Direct fabric, which remains intact even without edge binding. Therefore, we opted for a raw edge finish to reduce weight. However, many customers have requested edge binding, so you will see this feature in subsequent models.。
Some customers preferred not to have too many hoods, so we also created a sample of the crew neck tee.
Initially, we also considered using a raw edge finish, but it caused the neckline to hang unevenly, as shown below:
We later decided to use elastic binding instead:
The pink fabric has been entirely used to make crew neck tees, available exclusively in XS/S sizes for petite girls, and is expected to be released in May or June.
We originally considered using a four-needle flat seam technique, which is common in form-fitting sportswear. The advantage is that it reduces friction against the skin, but the downside is the high cost and difficulty in production. However, this was not a major issue for the skilled craftsmen.
Ultimately, since the garment is intended as a mid-layer rather than a base layer, and using a raw edge finish with overlock stitching can address friction issues, we decided not to use the four-needle technique for now.
Many people are interested in the pants, which are suitable for sleeping at camp. The difference from down pants is that these have better breathability and won’t create a feeling of moisture clinging to the down fabric. However, for those who are sensitive to the cold, down pants will still provide better warmth at camp (in static conditions).
Since the pants come into direct contact with the skin, in addition to overlock stitching, they also feature flatlock seams to prevent friction and discomfort.
Next, we have the footies, also designed for warmth while sleeping at camp. They similarly use overlock stitching with edge binding.
Because the top has an elastic binding, it can be worn alone or over wool socks.
The sole design does not conform to the specific foot shape but accommodates a wider range of foot lengths, so fewer sizes will be needed in the future.
Final
Since we are entering the market in 2024 and wool is already one of our core products, we aim to promote its complementary use through a special gift package launch. Future new products will be sold through our official website. Although we will not use the gift package approach for these, our prices are competitive, and website members can enjoy a 20% discount code. We recommend interested customers to take advantage of this offer for better value.
We are also continuously developing other products such as vests and arm sleeves, common in mountaineering gear. Additionally, since our garment factory produces laundry bags, there is a possibility of including them in future packaging.
We welcome any ideas or requests you may have, which can be communicated through our official LINE account (ID: @wowool).
Comments