Custom Underwear Manufacturer

We cut a swatch from the same fabric roll your order will be cut from. It is washed and dried on a repeated domestic cycle following ISO 6330, the standard laundering procedure used for textile testing, and the dimensional change is read the way AATCC 135 reads it. We then measure how much of its original dimension the elastic and the knit hold on to.

You see those numbers before we cut your bulk. If the fabric drifts from what your approved sample did, you find out while it is still fixable, not when your customers start emailing you.

This matters more on underwear than on any other knit garment. A t-shirt that relaxes half a size is still a t-shirt. A waistband that relaxes is a returned product, and it is the single most common reason a first underwear drop does not reorder.

Briefs, boxer briefs, trunks and woven boxers, in cotton, cotton/modal and cotton/spandex jersey. Custom pouch construction, contrast panelling and jacquard waistbands are all standard development work for us.

Briefs, bikinis, hipsters and high-waist styles, with picot or raw-edge finishing, gusset lining to your spec, and lace trim integration where the design calls for it.

We do not make seamless underwear. Seamless is knitted on circular seamless machines, which is a different production technology from cut-and-sew, and pretending otherwise would waste your sampling budget. If seamless construction is central to your product, we are not your factory.

Everything below is developed to your spec, not chosen from a catalogue.

Waistband. Custom woven jacquard band with your brand name repeated along it, or covered elastic with a printed or heat transfer mark for a softer finish. Jacquard tooling is a separate step, so send vector artwork with your tech pack.

Fabric. Cotton, cotton/modal, cotton/spandex jersey, and viscose from bamboo. Note that United States labelling rules under 16 CFR Part 303 require the wording viscose from bamboo or rayon from bamboo rather than simply bamboo, and we print your care labels exactly as you supply them, so it is worth getting that wording right before artwork approval.

Labels and packaging. Woven main label, printed care and content label, tagless heat transfer, poly bag, printed box or hangtag.

Five stages. The one most suppliers skip is the fourth, and it is the one that decides whether your second order happens.

You send a tech pack, or a reference pair plus your target market, quantity and price point. Roughly half our programmes start from a reference garment rather than a finished tech pack. What we do need either way is the size range you are selling into and the fit you want, because underwear fit is not something we can infer from a photo.

Our pattern room drafts the block and produces a proto. On underwear this is where pouch shape, rise, leg opening and gusset width get settled. Expect one or two rounds; a brand that nails fit on the first proto is lucky rather than well briefed.

The approved sample becomes the reference for bulk. Approve it on a real body in the size you sell most of, not flat on a table. Waistband tension in particular reads completely differently worn than measured.

Before cutting, we test the actual production roll and send you the numbers. This is the stage almost nobody runs, and it is why so many first underwear drops come back soft in the waist after a month of customer wear. If the roll drifts from what your sample did, we deal with it before it becomes 800 pieces of inventory.

Cut, sew, AQL 2.5 inspection, then FOB Shanghai or Ningbo. You approve inspection results before the balance payment moves.

You do not need to know all of this before contacting us, but the more of it you have decided, the fewer sampling rounds you pay for.

Fabric weight. Underwear jersey typically sits between 140 and 200gsm. Lighter reads as premium and breathes better; heavier feels more substantial on the shelf and survives washing longer. Tell us which end you want to sit at and why, and we will steer the fabric rather than guess.

Spandex content. Usually 5 to 10 percent. This is the number that governs recovery, and it is the one buyers most often leave unspecified. More spandex is not automatically better; it changes how the garment ages.

Gusset. Whether the gusset is lined, what it is lined with, and whether it is sewn in as a separate panel or as part of the body. On women’s styles this is a hygiene and comfort decision as much as a construction one, and it is worth deciding rather than defaulting.

Waistband. Exposed jacquard elastic with your brand name woven in, or covered elastic for a softer finish. Jacquard requires its own tooling lead time, so it needs to be decided early rather than added at the end.

Edge finish. Picot, raw-edge bonded, or folded and coverstitched. This is the detail that most visibly separates a $4 pair from a $12 pair on a customer’s first touch.

DTC underwear and basics brands launching a first range, or replacing a supplier who could not hold consistency between sampling and bulk.

Loungewear and sleepwear brands extending into underwear. This is the most common route we see, and it is efficient: the same buyer, the same fabric conversations, and the same production window as your loungewear programme.

Amazon and marketplace sellers who need private label with real labelling compliance rather than a generic product with a logo added.

Who it is not for: anyone who needs seamless construction, and anyone whose entire proposition rests on beating a 30-piece minimum. We are neither of those factories, and saying so early saves us both a month.

Names are withheld at the clients’ request. Everything below is from real production runs.

Underwear usually travels with the rest of a comfort range. If you are building out a full line, our loungewear manufacturing and pajama manufacturing programmes run on the same knit lines, and brands starting their first production run often begin at our low MOQ clothing manufacturing page.