Custom Swimwear Padding: Real Mold Cost and Rebate
Custom foam padding — for push-up, coverage, or shaped support — is one of the few customization categories in swimwear with an actual cost-recovery mechanism built in, not just a one-time fee. Here's the real number, and how the rebate works.
The Real Cost: $400 Per Size, No MOQ
A custom padding mold costs $400 USD per size, with no MOQ requirement — meaning you can order custom-molded padding without committing to a large minimum quantity to unlock the customization in the first place. This covers three real, distinct padding types: push-up padding (for smaller busts wanting lift), integrated padding (for larger busts needing fuller coverage support), and special-shaped padding (shell-shaped and other non-standard forms).
The Rebate: The Mold Fee Comes Back
This is the detail worth knowing before writing padding off as a fixed sunk cost: the full $400 mold fee gets rebated once your cumulative order reaches 20,000 units. This is specifically designed to lower the real upfront barrier for a startup brand committing to a custom padding shape — you pay the tooling cost once, and it's returned in full as your order volume scales, rather than staying a permanent cost baked into every unit indefinitely.
Why Padding Type Matters for Sourcing
Padding isn't a single generic component — the three real types above solve different fit problems, and specifying the right one matters more than the mold cost itself. This connects directly to the real construction elements that separate genuine structural support from a padding-only solution: padding alone changes silhouette, while real support (underwire, power mesh, boning) changes how a garment actually holds up under movement. Knowing which one your design actually needs — padding, structural support, or both — is the real decision, with the $400 mold fee being a secondary consideration once that's settled.
Where This Fits in Your Overall Budget
Padding is one of twelve real customization categories in our complete Budgeting Guide — see the full breakdown alongside hardware, packaging, and fabric development costs.
FAQ
Q: Does the padding mold fee apply per style, or once for the whole brand?
A: Per size/shape — a $400 mold fee applies to each distinct padding size or shape you customize, since each requires its own tooling.
Q: How does the 20,000-unit rebate threshold work — is it per style or cumulative?
A: It's cumulative — once your total order volume across the relevant padding reaches 20,000 units, the mold fee is rebated in full.
Q: Is there a minimum order to use custom padding at all?
A: No — there's no MOQ requirement for custom padding, which makes it accessible for a startup brand's first order rather than something that only makes sense at scale.
Q: Should I choose padding or structural support (underwire, power mesh) for my design?
A: It depends on what you're solving for — padding changes silhouette and coverage, while structural elements change how the garment actually performs under movement. Many designs use both together.
Planning a padded style and not sure which padding type fits your design? Send us your reference — we'll walk you through the real options and cost.