CASE STUDY 3: Building a Dual-Purpose Domestic Facility

Problem:
Designing products with a low environmental impact required a commitment to long-lasting quality and repairability. Prioritizing durability aligned with sustainability goals, but created operational challenges around maintaining consistent quality standards, enabling repairs, and supporting product longevity at scale.

Strategy:
Establish a domestic facility that could serve as both a repair center and a limited-run production site, intentionally designed to uphold quality standards, support sustainability goals through lifecycle extension, and offset operational costs by generating revenue through prototyping and quick-turn production.

Execution:

  • 1. Established a fully equipped in-house production facility

    Developed a domestic manufacturing site with end-to-end production capabilities to support agile sampling, repairs, and short-run production.

    • Built and equipped a cut-and-sew facility with scalable infrastructure

    • Streamlined on-site sampling and implemented efficient material stocking systems

  • 2. Recruited and led a domestic production team

    Formed and managed a skilled team dedicated to quality output and lean operations.

    • Hired and trained internal production staff for technical builds

    • Maintained consistency in quality standards while meeting production timelines

  • 3. Launched a repair and alterations program

    Implemented an in-house service model to handle product repairs and modifications for lifecycle extension.

    • Designed workflows to support customer-submitted alterations and repairs

    • Contributed to brand sustainability goals by reducing replacement-based consumption

  • 4. Developed small-batch B2B prototyping and production

    Created a revenue-generating model for prototyping and quick-turn manufacturing.

    • Enabled B2B clients to launch limited-run collections and iterate faster

    • Achieved high product margins through low-overhead production strategies

  • 5. Lead deadstock and recycling initiaves

    Activated circular systems to reduce waste and repurpose materials creatively.

    • Transformed production scraps and unused materials into marketable accessories

    • Partnered with eco-aligned brands to install wetsuit recycling drop-off points.

Results

  • Extended product lifespan by over 3x through the implementation of customer repair and alteration services.

  • Reduced product development cycles to under 3 months by leveraging the in-house production facility for rapid prototyping and sampling.

  • Generated a new revenue stream with 80% product margins through B2B small-batch and quick-turn production services.

  • Formed collaborative partnerships with aligned brands such as Kassia and launched upcycled products including a deadstock wetsuit koozie.

  • Established a wetsuit recycling drop-off program in collaboration with Suga Yoga, enabling closed-loop sustainability for multiple brands.