Puffer Jackets
A puffer is the clearest case in outerwear where the same fill weight produces completely different garments depending on baffle construction. We build puffer programmes from 10D ultralight shells for layering pieces up to 20D and heavier cloth for winter mainlines, in sewn-through, welded and box-wall baffle, with duck down from 550 to 800 fill power or synthetic alternatives from 80 g/m².
Puffer constructions we run
Baffle construction is the decision that shapes everything else — cost, warmth, weight and how the garment looks.
Sewn-through baffle
Needle-punched channels. Lightest and cheapest, with cold spots at every seam line.
Box-wall baffle
Internal mesh walls give full loft with no stitched cold spot. Warmest and most expensive.
Welded baffle
Ultrasonic or heat-welded channels. Clean look, no needle holes, less down leakage.
Quilted panel
Decorative quilting over a flat fill layer. Fashion-led, less technical.
Hybrid construction
Insulated core with stretch fleece or softshell side panels for movement.
Reversible puffer
Two-face construction with reversible zips and clean internal finishing.
Choosing the baffle: what it actually costs you
Three constructions, three very different outcomes. This is the table we walk buyers through.
| Sewn-through | Lowest cost, lightest. Cold spot at each stitch line. Best for mild climates and layering pieces. |
|---|---|
| Box-wall | Highest warmth for the fill weight, no cold spots. Higher labour cost, heavier. Best for genuine cold. |
| Welded | Cleanest aesthetics, no needle holes. Requires compatible shell fabric. Higher tooling cost, best at volume. |
Fill: down versus synthetic
Down wins on warmth for weight and compresses better, but loses loft when wet and costs more. Synthetic holds loft when damp and is cheaper, but is heavier for the same warmth. For a European winter mainline most brands run down at the core of the range and synthetic at the entry price point; for wetter, milder markets synthetic often wins across the board.
- Duck down 550-800 fill power, RDS-certified option available
- Synthetic fill 80-300 g/m², recycled options with GRS certification
- Down-proof shell construction tested for leakage before bulk
- Fill power and weight verified on incoming material, not just on the supplier certificate
Shell, hardware and finishing
| Shell fabric | Polyamide or polyester 10D-20D for ultralight, 20D-50D for mainline |
|---|---|
| Finish | Down-proof calendered, PFAS-free C0 DWR |
| Baffle | Sewn-through, box-wall, welded or quilted |
| Fill | Duck down 550-800 fill power, or synthetic 80-300 g/m² |
| Zippers | YKK coil or Vislon, reverse coil for clean look |
| Hem & cuffs | Elasticated, drawcord, or lycra-bound |
| Hood | Fixed, detachable, or helmet-compatible |
| Recycled | GRS-certified recycled shell and fill |
Compliance and testing
- OEKO-TEX Standard 100 on shell, lining and fill
- RDS certification available for responsible down
- GRS transaction certificates for recycled shell and fill
- Down-proof testing on shell fabric before bulk cutting
- Fill power verification on incoming down
- PFAS-free declarations for C0 finishes
- BSCI-audited partner factories
MOQ, sampling and lead times
| MOQ | 400 pcs per colour, sizes mixed within the colour |
|---|---|
| Sampling | 7-10 days in stock fabric; 15-20 days for sourced or custom-dyed shell |
| Bulk lead time | 35-55 days after PP approval |
| Quote turnaround | Within 24 hours |
Questions buyers ask
What is the MOQ for custom puffer jackets?
400 pcs per colour with sizes mixed within that colour. Several styles on one fabric platform can often share the minimum.
Should I use down or synthetic fill?
Down for warmth-to-weight and compressibility in dry cold; synthetic where the garment will get wet or where entry price matters. Most European ranges run both at different price points.
What is the difference between sewn-through and box-wall?
Sewn-through stitches the shell straight to the lining, leaving a cold spot at every channel. Box-wall uses internal mesh walls so the fill lofts fully with no cold spot — warmer, but heavier and more labour-intensive.
Do you offer RDS-certified down?
Yes. RDS-certified down is available with the transaction certificate issued against your order.
Can you do welded baffle construction?
Yes, subject to shell fabric compatibility and a volume that justifies the tooling. We will confirm both at quotation stage.
How do you stop down leaking?
The shell is specified down-proof and tested before bulk cutting, needle size and seam construction are controlled, and finished garments are checked for leakage before packing.
Tell us what you need
Send a tech pack, a reference sample or just a target price. We reply within 24 hours with a fabric suggestion, a cost indication and a sampling plan.
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