Demand Manufacturing
Niche Fashion
Freedom Rave Wear | Made to Order
Freedom Rave Wear is a festival fashion company based in San Diego. They are a family business, founded with a commitment to make quality goods locally and sustainably. When they started in 2014, co-founder Alyssa Erickson made everything by hand in their apartment. Now FRW is an agile made-to-order microfactory in San Diego with 10 employees.
“We were broke kids, we had no investment and our parents thought we were crazy!” laughs Alyssa thinking back to when she and her husband Michael Hodgen started out.
Because they did not have much money to keep materials on hand, they would need to get paid for an order before they could by any of the fabric required to make the product. As they grew they were able to contract out to cut and sew companies for bulk production in nearby Los Angeles, but that came with its own set of challenges.
“I had to make sure all the ratios were right across eight sizes,” Alyssa explains. For example, they might really need 17 smalls and 1 extra-large in one color, but 12 extra-larges and only 5 smalls in another color, however they were constrained by size ratio order requirements by contractors. This meant they always had understock in some SKUs and overstock in others.
After they got the TUKAcut Laser cutting machine, and a sublimation fabric printer FRW was able to transition to a made to order model and only make the styles after they sold. This enabled them to meet the demand of their customers no matter what sizes were purchased, and reduced the amount of dead inventory on hand due to over-buying.
According to Michael, FRW has seen a 50% reduction in their inventory costs since they transitioned to made to order. The money saved is now able to be put towards more technology and investing in things that will grow the business.
“It wasn’t overnight that we got to realize those benefits,” he explains. “It took years to build up these inefficiencies and to deconstruct those takes time.”
Michael recommends fashion businesses to properly identify the problems they have and to partner with people who have experience and expertise in those areas. This was one of the reasons FRW chose to work with Tukatech as they expanded their in-house production capabilities. They didn’t want to guess when it came to investing in the growth of their business; they wanted to work with people who had “been there, done that” when it came to microfactories.
The benefits of using technology were not only seen in cost savings. Michael compared FRW’s creative capabilities before and after their machines to “a small bicycle and racing it against a performance Tesla.”
Before they had a sublimation fabric printer they were limited in their creativity by what fabrics they could source. Although they were quick to buy the latest fabric designs, they would only have a month or so before their competition would catch up, since most other festival fashion companies buy their fabric from the same places.
Now they keep stock only of white fabric and print whatever designs they want. This has even enabled them to collaborate with print designers for the most unique festival looks.
FRW has an active, engaged social media following, which they use to test out new print and silhouette combinations. Alyssa says they use polls and surveys to find out what their customers want. They can make a small batch of new products to see what sells, and then only produce the most popular styles.
“When you’re making things it’s I hope this is going to sell, or I think this is going to sell,” she shares. “A lot of the times, that wasn’t the case.”
As a company committed to sustainability, FRW is not content to throw away dead inventory, or even scrap fabric. One of the ways they use social media is to host “story sales,” where they post old inventory, seconds, or even samples. Story sales are well-received by the FRW audience because they might see an older design from a previous season they missed, or a truly one-of-a-kind sample that never made it to production.
Rather than throw away fabric scraps, Alyssa repurposes them for smaller products like scrunchies, masks, or even packaging. For their swim brand, Never Lost Swim, the scraps become matching drawstring storage bags.
FRW had a big challenge in 2020 when all festivals worldwide were cancelled due to the pandemic. Overnight, there was zero demand for festival fashion, their core product. Alyssa and Michael had to think creatively about how to utilize the equipment they had purchased to keep their business afloat.
They started Fabric Punch as a fabric printing service offered to other fashion businesses. Many of those businesses are one-person startups who operate similar to FRW early on: they have to get an order so they have money to buy materials. Alyssa keeps a quick turnaround so these companies have plenty of time to complete their order for the end customer.
Since Alyssa has a lot of experience with printing custom fabric for her own business, she is able to offer her knowledge back through Fabric Punch, even recommending scale and repeat options depending on the end product.
TESTIMONIAL LINKS
Freedom Rave Wear Website: https://freedomravewear.com/
Fabric Punch Website: https://fabricpunch.com/