Baseball Jersey
Fabric
Polyester, Blends Spandex
Embroidery
High Density Embroidery Machine
Printing
Screen Printing, Thermal Transfer, Digital Direct Printing, Etc.
ECO
OEKO-TEX®
- Design and Concept Development
- Brand/Team Collaboration: Collaborate with teams or brands to create designs incorporating team colors, logos, player numbers, and sponsor branding.
- Technical Sketches: Use CAD software to draft patterns, including sleeve styles, collar types (V-neck, button-up), and fit (traditional or athletic cut).
- Prototyping: Produce a sample jersey to test fit, comfort, and aesthetics.
- Material Selection
- Fabric:
- Polyester: Dominates due to durability, breathability, and moisture-wicking properties (e.g., 100% polyester or blends with spandex for stretch).
- Performance Enhancements: Antimicrobial treatments, UV protection, or lightweight meshes for ventilation.
- Sustainability Options: Recycled polyester (rPET) or organic cotton blends for eco-conscious lines.
- Embellishment Materials: Threads for embroidery, heat-transfer vinyl (HTV), or sublimation inks for graphics.
- Fabric:
- Pattern Making and Grading
- Base Pattern: Create a master template based on the prototype, defining seams, panels, and proportions.
- Size Grading: Adjust the base pattern to produce sizes (S–XXXL) while maintaining design integrity.
- Digital Cutting Files: Convert patterns into digital files for automated cutting machines.
- Fabric Cutting
- Layering: Stack fabric rolls on cutting tables, often using laser-guided systems for precision.
- Automated Cutting: CNC machines or laser cutters slice fabric into panels (front, back, sleeves, collars).
- Waste Reduction: Nest patterns to minimize material waste.
- Sewing and Assembly
- Panel Stitching: Sew shoulder seams, side seams, and sleeves using flatlock stitches for durability and comfort.
- Collar and Placket Construction: Attach collars and button plackets (if applicable) with reinforced stitching.
- Hemming: Finish edges with coverstitch or blind-hem machines.
- Graphics and Branding Application
- Screen Printing: Apply logos, numbers, and names using plastisol or water-based inks for vibrant colors.
- Embroidery: Stitch team logos or patches onto chest, sleeves, or back (common for premium jerseys).
- Sublimation Printing: For all-over designs, dye fabric using heat to embed patterns permanently.
- Heat Transfers: Use HTV for small graphics or sponsor decals.
- Quality Control
- Stitch Integrity: Inspect seams for consistency and durability.
- Color Accuracy: Ensure logos and fabrics match Pantone references.
- Fit Testing: Verify sizing against standardized mannequins or wear-testers.
- Compliance Checks: Test fabrics for safety (OEKO-TEX®) and performance (moisture-wicking efficacy).
- Labeling and Tagging
- Care Tags: Attach labels with washing instructions and material composition.
- Brand Tags: Sew in woven labels with logos and licensing information.
- Hang Tags: Add promotional or size-specific tags for retail display.
- Finishing and Packaging
- Steam Pressing: Remove wrinkles and set seams using industrial steamers.
- Folding: Machine-fold jerseys for uniformity.
- Packaging: Wrap in polybags or box for retail; bulk-pack for team orders.
