Fourbital x Darn Tough: From Excess to Essential

At Fourbital Factory, what we make tells a story, and that story starts with how we choose to make every beanie. So when our neighbors at Darn Tough reached out with an idea — to take excess yarn from their sock production and turn it into a small batch of winter beanies for their Black Friday gift with purchase — we jumped at the opportunity.

Together, we created a limited run of thoughtfully made beanies using leftover materials from Darn Tough’s Mill and expertise from our team in Burlington, Vermont. The result: a custom beanie built to last and stitched with shared values. 

Thinking Outside the Box

Like most apparel manufacturers, Darn Tough ends up with small quantities of premium yarn — Merino Wool and other specialty fibers — that don’t quite fit into a standard sock run. Instead of shelving or tossing the remaining material, they asked if we could help turn it into something useful. 

We said yes — and got to work. Over the next several weeks, our team sorted excess yarn by hand, collaborated on the perfect color palette, and tested various knit patterns until a prototype emerged that felt just right.

From Vermont. By Vermonters. A Product That Reflects Our Values

At Fourbital, we’re proud to be a beanie manufacturer that partners with brands who share our commitment to local production, intentional design, and durable materials. This project wasn’t about making a quick run of swag — it was about making something meaningful.

“Working with the Darn Tough team to develop beanies from their excess yarn has been so rewarding. Bringing together their materials and our machines required creative problem solving from the whole team, and the end result is a product we’re really proud of.” — Gail Nilsson, Director of Operations, Fourbital Factory 

These beanies were built with the same purpose-driven approach that defines both of our brands, and they’re meant to be worn for years, not forgotten.

What Collaboration Looks Like

This project came together because both of our teams believe in doing things thoughtfully, and doing them well. From Darn Tough’s dedication to knitting socks in Vermont with globally sourced yarns to our passion for USA-based beanie and apparel manufacturing, the product we created was one of shared intention.

“There’s a certain pride in a project that comes from being able to walk out onto the factory floor and talk directly with the people building your product. That’s what made this collaboration so successful — it reduced waste, supported local jobs, and showed what’s possible when a small community comes together.” — Marcos Biggs, Product Developer, Darn Tough

Where Can I Find These Beanies?

The limited-edition beanies will be a free gift on Cyber Monday for orders $150 and over on DarnTough.com, but their impact goes beyond the holiday season. They’re a reminder of what’s possible when companies choose to work with neighbors and invest in thoughtful production.

At Fourbital Factory, we’re here to help brands bring their ideas to life, whether it’s a custom design, a fast turnaround, or a new approach to conscious production. And we’re proud to be part of the growing movement of manufacturers keeping production in Vermont, USA.

About the Author

Fourbital Factory is a Vermont-based manufacturer proving that local production can deliver it all: quality, speed, and ethics. We streamline the supply chain, obsess over every detail, and keep our work Community First, because we believe the strongest products come from the strongest communities.

Contact Information

Website: Fourbital Factory
Custom Beanies: info@fourbitalfactory.com
Phone: (802) 662-1572
Address: 750 Pine Street, #2, Burlington, Vermont