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.
  • 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.