Behind the Build: Bringing Tommy Bahama’s Display to Life

Creating standout visual displays is a craft that requires careful attention to detail, problem-solving, and close collaboration with clients. Today we’re pulling back the curtain on one of our recent projects with Tommy Bahama to give you a better sense of this process.

From concept to execution, follow along as we bring a denim-themed store display to life, including our approach to design, communication, and commitment to delivering results that you and your customers will love.

The Initial Project Request

Tommy Bahama storefront picture to show the type of stores involved.

In late May, Tommy Bahama reached out to Circle Visual for help on a denim themed display project that would be rolled out to all their stores by August 30. The project included multiple components, such as:

• Cut denim squares and strips to fill oversized glass jars

• Hanging denim banners

• Denim-covered folding screens

• Freestanding denim-covered monstera leaves (the most challenging component)

Concept and Design Requirements

The goal was to create denim-covered monstera leaves that were freestanding. Initially, Tommy Bahama shared inspiration photos featuring metal leaves on square metal stands.

The inspiration photo of metal leaves on square metal stands

They wanted to keep a similar aesthetic but have the leaves covered in denim fabric on both sides, with slightly flexible stems. There was also some early discussion of adding sewn leaf veining, which was eventually dropped.

We quoted two options for leaf quantities: 130 or 300 units, all of the same shape.

Creating the Perfect Monstera Leaf

Tommy Bahama sent us an artificial monstera leaf as a reference. We scanned it in sections and combined the scans to create a complete digital version, adjusting the design for manufacturability. We sent the digital proof to them for approval — the approved final leaf silhouette was 16 inches wide by 18 inches tall.

The artificial monstera leaf Tommy Bahama provided as a reference. This shows the base shape we used to develop the final design.

The scanned sections of the monstera leaf. This step is part of converting the physical leaf into digital artwork.

The finalized digital version of the leaf silhouette, sent for approval.

After some discussions, the order was finalized at 104 individual leaves, split into two stem heights: 18 inches and 22 inches.

Selecting the Right Denim Fabric

We presented Tommy Bahama with three 7-ounce denim swatches: dark, medium, and light. They chose the dark denim for both sides of the leaves.

The three denim swatches (dark, medium, light) that were presented to Tommy Bahama.

Building the Leaves

1. Creating the Cutting Dye

The leaf shape was laser-cut into wood to serve as the base for the cutting dye. Metal cutting blades were then added to create precise cuts of the leaf outline.

Example image of a leaf block and blades used in the cutting dye. It’s not the exact one for this project but illustrates the dye-making process.

2. Cutting and Assembly

We cut all the approved dark denim fabric into the desired leaf shape. To provide structure without adding weight, we sandwiched black chipboard (similar to card stock in thickness) between two denim leaf cutouts.

A leaf sandwiching the black chipboard between two denim layers. Note the internal structure of the leaves.

3. Stem Construction

Initially, we planned to sew denim sleeves around the stems, but the tests proved too bulky. We switched to wrapping the stems in denim fabric and securing the edges with adhesive.

The stems wrapped in denim fabric, showing the final stem construction method.

4. Prototype Approval

We created two prototypes (one of each stem size) and shipped them to Tommy Bahama. The feedback was positive, with a single note to reduce the thickness of the aluminum stems for increased flexibility.

Image depicting the two different stem heights. Use this to show how the leaves would look at the approved sizes (18” and 22”).

Final Production and Shipment

Once the prototypes were approved, we moved forward with full production. The leaves were packed individually into sets and secured in cardboard boxes. The remaining project components were included in the shipping box.

The production stage or leaves in progress, illustrating the scaling up of the process from prototype to full production.

The completed leaves drying after assembly.

The final packed elements in the shipping box.

Project Outcome

The final denim monstera leaves were delivered on time, and Tommy Bahama was thrilled with the end result. Seeing our work transform their stores and elevate the shopping experience was a rewarding reminder of why we do what we do.

The finished leaves at Walnut Creek, CA.

Considering a project for your own store? Get in touch today.

If you need some inspiration first, check out our portfolio and some of the services we provide.