Complete pipeline for AOP Reversible Bucket Hat (catalog 654) on Printful. CUT-SEW all-over sublimation on 100% polyester. Reversible — 4 independent print panels + 2 labels. Use when creating AOP bucket hat products, designing reversible bucket hats, generating bucket hat mockups, or managing all-over-print headwear. Covers multi-panel design, variant management, mockup generation, and Supabase integration.
Scanned 6/1/2026
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---
name: Printful AOP Reversible Bucket Hat Production
description: >-
Complete pipeline for AOP Reversible Bucket Hat (catalog 654) on Printful.
CUT-SEW all-over sublimation on 100% polyester. Reversible — 4 independent
print panels + 2 labels. Use when creating AOP bucket hat products,
designing reversible bucket hats, generating bucket hat mockups, or
managing all-over-print headwear. Covers multi-panel design, variant
management, mockup generation, and Supabase integration.
---
# Printful AOP Reversible Bucket Hat Production Pipeline
Full production pipeline for SKAPARA AOP Reversible Bucket Hats on Printful. This is a CUT-SEW product — the design is sublimated onto white polyester fabric before the hat is assembled. Both the outside and inside surfaces are independently printable, making it a truly reversible accessory.
For DTG-based apparel products, see the `printful-cc1717` or `printful-tshirt` skills instead.
For embroidered headwear, see the `printful-6089m-embroidery` or other embroidery skills.
---
## Product Specifications
| Property | Value |
|---|---|
| **Product** | AOP Reversible Bucket Hat |
| **Catalog ID** | 654 |
| **Technique** | CUT-SEW (all-over sublimation) |
| **Material** | 100% polyester |
| **Weight** | 8.1 oz/yd2 (275 g/m2) |
| **Colors** | White only (sublimation base) |
| **Sizes** | XS, S/M, L/XL |
| **Construction** | Reversible — both sides independently printable |
| **Producer** | Printful (Latvia — CUT-SEW in-house) |
| **EU Fulfillment** | LIKELY YES (cut-sew in-house Latvia) |
| **Base Price** | 21.74 EUR |
---
## When to Use
- Create a new AOP reversible bucket hat product on Printful
- Design all-over-print patterns for a reversible bucket hat (4 panels + 2 labels)
- Generate mockups for AOP bucket hat products
- Update Supabase with AOP bucket hat product data
- Manage bucket hat variant sizing (XS, S/M, L/XL)
---
## AOP / CUT-SEW Technical Notes
**How CUT-SEW sublimation works:**
1. Your design is printed onto transfer paper using sublimation ink
2. The ink is heat-pressed onto flat white polyester fabric panels
3. The fabric is then cut and sewn into the final product shape
4. Result: seamless, edge-to-edge print coverage on every surface
**Design requirements:**
- **DPI**: 150 (standard AOP resolution)
- **Fill mode**: `cover` — design fills the entire panel area
- **Format**: PNG, no transparency needed
- **Color mode**: sRGB (sublimation inks reproduce sRGB accurately)
- **Base fabric**: White only (sublimation requires white/light base)
- **Each panel is a SEPARATE design file** at exact canvas dimensions
**Color considerations:**
- Sublimation produces vibrant, saturated colors on polyester
- Very dark designs (near-black) may show slight variation at seams
- Neon/fluorescent colors will NOT reproduce accurately — use standard sRGB gamut
- White areas = no ink = shows the white base fabric
---
## Multi-Panel Design — REVERSIBLE HAT
This hat has **6 placements** — 4 print panels + 2 labels. The CRITICAL feature is that the hat is REVERSIBLE: the wearer can flip it inside-out to show a completely different design.
### Design Strategy
| Panel | Purpose | Design Approach |
|---|---|---|
| `outside_front` | Primary exterior front | Main AOP pattern (hero design) |
| `outside_back` | Primary exterior back | Continuation or complement of front pattern |
| `inside_front` | Reversible interior front | Contrasting/complementary AOP pattern |
| `inside_back` | Reversible interior back | Continuation of inside pattern |
| `label_outside` | Exterior label | SKAPARA mark (S isotipo or wordmark) |
| `label_inside` | Interior label | SKAPARA mark (matching interior aesthetic) |
**GOLDEN RULE:** Design the outside and inside as TWO DISTINCT but brand-coherent looks. The reversibility IS the product feature — do not waste it with identical designs.
**Pattern ideas for reversible hat:**
- Outside: bold pattern / Inside: subtle tone-on-tone version
- Outside: dark colorway / Inside: light colorway (same motif)
- Outside: graphic/illustrated / Inside: geometric/abstract
- Outside: brand pattern / Inside: complementary solid-feel with subtle repeat
---
## Placements & Canvas Sizes
All canvases at 150 DPI:
| Placement | Printfile | Canvas (px) | Physical | Fill | Cost |
|---|---|---|---|---|---|
| `outside_front` | PF#410 | 2700 x 3150 | 18.0" x 21.0" | cover | included |
| `outside_back` | PF#410 | 2700 x 3150 | 18.0" x 21.0" | cover | included |
| `inside_front` | PF#410 | 2700 x 3150 | 18.0" x 21.0" | cover | included |
| `inside_back` | PF#410 | 2700 x 3150 | 18.0" x 21.0" | cover | included |
| `label_outside` | PF#411 | 450 x 300 | 3.0" x 2.0" | cover | included |
| `label_inside` | PF#411 | 450 x 300 | 3.0" x 2.0" | cover | included |
**IMPORTANT:** All 6 placements are included in the base price (21.74 EUR). No additional placement charges.
**Total design files needed: 6** (or fewer if outside_front == outside_back pattern, etc.)
---
## Branding for AOP Products
Since AOP covers the entire surface, branding is integrated INTO the design:
- **Label placements** (`label_outside` + `label_inside`): Use SKAPARA S mark or wordmark
- **Panel designs**: Incorporate SKAPARA branding elements subtly into the all-over pattern (watermark repeat, pattern element, etc.)
- **No separate branding placement** — everything is part of the AOP design
**Label design specs:**
- Canvas: 450 x 300 px @ 150 DPI
- Recommended: SKAPARA S mark centered, white or dark depending on label background
- Keep it simple — this is a small woven-label-sized area
---
## Printful API Reference
**Auth headers (ALL requests):**
```
Authorization: Bearer ${PRINTFUL_API_TOKEN}
X-PF-Store-Id: ${PRINTFUL_STORE_ID}
Content-Type: application/json
```
**Store ID:** `17795695` (Skapara)
**Rate limits:**
- General API: ~120 req/min. Use `delay(2000)` between calls
- Mockup Generator: ~10 req/min. Use `delay(10000)` between tasks
- On 429: read `x-ratelimit-reset` header, wait that many seconds, retry
**Shared utility:** For scripts, use `import { createPrintfulClient } from './lib/printful-rate-limiter.mjs'`
---
## Workflow: Create New AOP Bucket Hat Product
### Step 1: Design All Panels
Create 6 PNG files at exact canvas dimensions:
| File | Canvas (px) | Purpose |
|---|---|---|
| `bucket-outside-front.png` | 2700 x 3150 | Primary exterior design |
| `bucket-outside-back.png` | 2700 x 3150 | Exterior back design |
| `bucket-inside-front.png` | 2700 x 3150 | Reversible interior design |
| `bucket-inside-back.png` | 2700 x 3150 | Interior back design |
| `bucket-label-outside.png` | 450 x 300 | Exterior SKAPARA label |
| `bucket-label-inside.png` | 450 x 300 | Interior SKAPARA label |
### Step 2: Upload Designs to File Library
Upload to Supabase Storage first, then POST to Printful File Library:
```bash
# Upload to Supabase Storage
curl -X POST "${SUPABASE_URL}/storage/v1/object/designs/uploads/${FILENAME}" \
-H "Authorization: Bearer ${SUPABASE_SERVICE_KEY}" \
-H "apikey: ${SUPABASE_SERVICE_KEY}" \
-H "Content-Type: image/png" \
-H "x-upsert: true" \
--data-binary "@${LOCAL_FILE_PATH}"
# Get public URL
PUBLIC_URL="${SUPABASE_URL}/storage/v1/object/public/designs/uploads/${FILENAME}"
# Upload to Printful File Library
curl -X POST "https://api.printful.com/files" \
-H "Authorization: Bearer ${PRINTFUL_API_TOKEN}" \
-H "X-PF-Store-Id: ${PRINTFUL_STORE_ID}" \
-H "Content-Type: application/json" \
-d '{
"url": "'${PUBLIC_URL}'",
"filename": "'${FILENAME}'"
}'
```
Save the `id` from each response — needed for product creation.
Repeat for all 6 design files:
1. Outside front → `OUTSIDE_FRONT_FILE_ID`
2. Outside back → `OUTSIDE_BACK_FILE_ID`
3. Inside front → `INSIDE_FRONT_FILE_ID`
4. Inside back → `INSIDE_BACK_FILE_ID`
5. Label outside → `LABEL_OUTSIDE_FILE_ID`
6. Label inside → `LABEL_INSIDE_FILE_ID`
### Step 3: Create Sync Product
```bash
curl -X POST "https://api.printful.com/store/products" \
-H "Authorization: Bearer ${PRINTFUL_API_TOKEN}" \
-H "X-PF-Store-Id: ${PRINTFUL_STORE_ID}" \
-H "Content-Type: application/json" \
-d '{
"sync_product": {
"name": "Product Name — AOP Bucket Hat"
},
"sync_variants": [
{
"variant_id": 19255,
"retail_price": "39.99",
"files": [
{ "type": "outside_front", "id": OUTSIDE_FRONT_FILE_ID },
{ "type": "outside_back", "id": OUTSIDE_BACK_FILE_ID },
{ "type": "inside_front", "id": INSIDE_FRONT_FILE_ID },
{ "type": "inside_back", "id": INSIDE_BACK_FILE_ID },
{ "type": "label_outside", "id": LABEL_OUTSIDE_FILE_ID },
{ "type": "label_inside", "id": LABEL_INSIDE_FILE_ID }
]
},
{
"variant_id": 16360,
"retail_price": "39.99",
"files": [
{ "type": "outside_front", "id": OUTSIDE_FRONT_FILE_ID },
{ "type": "outside_back", "id": OUTSIDE_BACK_FILE_ID },
{ "type": "inside_front", "id": INSIDE_FRONT_FILE_ID },
{ "type": "inside_back", "id": INSIDE_BACK_FILE_ID },
{ "type": "label_outside", "id": LABEL_OUTSIDE_FILE_ID },
{ "type": "label_inside", "id": LABEL_INSIDE_FILE_ID }
]
},
{
"variant_id": 16361,
"retail_price": "39.99",
"files": [
{ "type": "outside_front", "id": OUTSIDE_FRONT_FILE_ID },
{ "type": "outside_back", "id": OUTSIDE_BACK_FILE_ID },
{ "type": "inside_front", "id": INSIDE_FRONT_FILE_ID },
{ "type": "inside_back", "id": INSIDE_BACK_FILE_ID },
{ "type": "label_outside", "id": LABEL_OUTSIDE_FILE_ID },
{ "type": "label_inside", "id": LABEL_INSIDE_FILE_ID }
]
}
]
}'
```
**Key points:**
- `variant_id` is the **catalog variant ID** from VARIANTS.md
- `retail_price` is the customer-facing price as string
- `files[].type` maps to placement names
- Same files array for all 3 size variants (same color = White)
- All 6 placements included at no extra cost
### Step 4: Set Pricing
| Size | Base Cost (EUR) | Retail Price (EUR) | Margin |
|---|---|---|---|
| XS | 21.74 | 39.99 | 45.7% |
| S/M | 21.74 | 39.99 | 45.7% |
| L/XL | 21.74 | 39.99 | 45.7% |
**CRITICAL:** Set prices in Printful FIRST. The cron sync margin fixer overwrites prices if margin falls below 35%.
### Step 5: Generate Mockups
```bash
curl -X POST "https://api.printful.com/mockup-generator/create-task/654" \
-H "Authorization: Bearer ${PRINTFUL_API_TOKEN}" \
-H "X-PF-Store-Id: ${PRINTFUL_STORE_ID}" \
-H "Content-Type: application/json" \
-d '{
"variant_ids": [16360],
"format": "png",
"width": 1000,
"files": [
{
"placement": "outside_front",
"image_url": "OUTSIDE_FRONT_PREVIEW_URL",
"position": {
"area_width": 2700, "area_height": 3150,
"width": 2700, "height": 3150,
"top": 0, "left": 0
}
},
{
"placement": "outside_back",
"image_url": "OUTSIDE_BACK_PREVIEW_URL",
"position": {
"area_width": 2700, "area_height": 3150,
"width": 2700, "height": 3150,
"top": 0, "left": 0
}
},
{
"placement": "inside_front",
"image_url": "INSIDE_FRONT_PREVIEW_URL",
"position": {
"area_width": 2700, "area_height": 3150,
"width": 2700, "height": 3150,
"top": 0, "left": 0
}
},
{
"placement": "inside_back",
"image_url": "INSIDE_BACK_PREVIEW_URL",
"position": {
"area_width": 2700, "area_height": 3150,
"width": 2700, "height": 3150,
"top": 0, "left": 0
}
}
]
}'
```
Poll task status:
```bash
curl "https://api.printful.com/mockup-generator/task?task_key=${TASK_KEY}" \
-H "Authorization: Bearer ${PRINTFUL_API_TOKEN}" \
-H "X-PF-Store-Id: ${PRINTFUL_STORE_ID}"
```
### Step 6: Download Mockups & Upload to Supabase Storage
Mockup S3 URLs expire in ~24h. Always download and re-upload:
```javascript
const storagePath = `designs/mockups/${productSlug}/${placement}.png`
const ts = Math.floor(Date.now() / 1000)
const publicUrl = `${SUPABASE_URL}/storage/v1/object/public/designs/${storagePath}?v=${ts}`
```
### Step 7: Update Supabase products Table
```javascript
const ts = Math.floor(Date.now() / 1000)
await supabase.from('products').upsert({
id: productId,
title: 'Product Name',
description: 'Creative marketing description only. No specs here.',
translations: {
es: { title: 'Titulo en espanol', description: 'Descripcion en espanol' },
de: { title: 'Titel auf Deutsch', description: 'Beschreibung auf Deutsch' }
},
category_id: 'CATEGORY_UUID', // FK to categories table (headwear / bucket-hats)
pod_provider: 'printful',
product_template_id: '654',
provider_product_id: String(pfProductId),
base_price_cents: 3999,
compare_at_price_cents: 5999,
images: [
{ src: `https://.../mockups/slug/outside-front.png?v=${ts}`, alt: 'Title - Outside' },
{ src: `https://.../mockups/slug/inside-front.png?v=${ts}`, alt: 'Title - Inside (Reversible)' }
],
product_details: {
safety_information: GPSR_HTML,
material: '100% Polyester (275 g/m2)',
care_instructions: 'Machine wash cold, gentle cycle. Do not bleach. Tumble dry low. Do not iron directly on print.',
print_technique: 'CUT-SEW (All-Over Sublimation)',
manufacturing_country: 'Latvia',
brand: 'SKAPARA',
blank: 'AOP Reversible Bucket Hat',
weight: '8.1 oz/yd2 (275 g/m2)',
construction: 'Reversible — both sides independently printed'
},
status: 'active'
})
// Create product variants (single color — White)
const sizes = [
{ size: 'XS', variantId: 19255 },
{ size: 'S/M', variantId: 16360 },
{ size: 'L/XL', variantId: 16361 }
]
for (const { size, variantId } of sizes) {
await supabase.from('product_variants').upsert({
product_id: productId,
color: 'White',
color_hex: '#ffffff',
size,
is_enabled: true,
external_variant_id: String(variantId),
image_url: `https://.../mockups/slug/outside-front.png?v=${ts}`
})
}
```
### Step 8: GPSR Compliance (MANDATORY for EU)
```html
<p><strong>Manufacturer:</strong> Printful Inc., Latvia</p>
<p><strong>Material:</strong> 100% Polyester (8.1 oz/yd2 / 275 g/m2)</p>
<p><strong>Construction:</strong> Reversible bucket hat, CUT-SEW assembly</p>
<p><strong>Print technique:</strong> All-over sublimation — dye-sublimation inks</p>
<p><strong>Care:</strong> Machine wash cold, gentle cycle. Do not bleach. Tumble dry low. Do not iron directly on print.</p>
<p><strong>Compliance:</strong> REACH, EU Regulation 2023/988 (GPSR)</p>
```
Store in `products.product_details.safety_information` (JSONB).
---
## Pricing Strategy
| Metric | Value |
|---|---|
| Base cost (all sizes) | 21.74 EUR |
| Recommended retail | 39.99 EUR |
| Margin | 45.7% |
| Minimum retail (35% margin) | 33.45 EUR |
All placements included — no additional costs.
---
## Known Issues & Gotchas
| Issue | Detail | Workaround |
|---|---|---|
| Seam alignment | AOP patterns may show slight misalignment at seams due to cut-sew process | Use patterns that tolerate seam breaks (abstract, geometric, repeat patterns) — avoid designs that require precise alignment across seams |
| White base shows at edges | If design has dark edges, white polyester may peek through at seam allowances | Extend dark areas slightly beyond canvas edges (bleed) |
| Temporary mockup URLs | S3 URLs expire ~24h | Always download + re-upload to Supabase Storage |
| Single color (White) | Cannot offer color variants — base is always white | Design variety comes from the AOP pattern itself |
| Reversible complexity | 6 separate design files needed | Plan both sides as a cohesive design package upfront |
| Cache-busting | Browser/CDN cache images by URL | ALWAYS append `?v=timestamp` when overwriting Supabase Storage files |
| Cloudflare 403 | Missing User-Agent causes blocks | Always include `User-Agent: POD-AI-Store/1.0` if using curl directly |
---
## Description Rules
**What goes in `description`** (creative text only):
- Product context, design story, reversibility feature highlight
- 2-3 sentences max, casual but smart tone
- Emphasize the reversible feature: "two looks in one", "flip it for a fresh vibe"
- Must be translated to EN, ES, DE
**What does NOT go in `description`:**
- Material composition -> `product_details.material`
- Care instructions -> `product_details.care_instructions`
- Manufacturing info -> `product_details.manufacturing_country`
- Safety/compliance -> `product_details.safety_information`
---
## Post-Creation Checklist
- [ ] Product appears in shop with correct category (headwear / bucket-hats)
- [ ] All 3 size variants show (XS, S/M, L/XL)
- [ ] Both outside and inside mockup images load correctly
- [ ] Price is correct (not overridden by margin fixer)
- [ ] GPSR safety information stored in `product_details`
- [ ] Description is clean (no HTML tags, max 2000 chars)
- [ ] Labels show SKAPARA branding
- [ ] Alt text follows pattern: "Title - Outside", "Title - Inside (Reversible)"
- [ ] Cache-buster `?v=timestamp` appended to all image URLs
- [ ] All 6 design files uploaded to both Supabase Storage and Printful File Library
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