Custom garment process & timeline
The journey of a custom garment, from a initial idea to a finished product, follows a structured process. Understanding these stages helps set realistic expectations for timing and collaboration.
Phase 1: Design & Development
Consultation & Briefing: We start by defining the garment's purpose, aesthetic, target audience, and key features (e.g., a performance jacket, a formal dress shirt, or branded merch).
Sketching & Tech Design: Designers create sketches, which are then translated into technical drawings (tech packs). These packs specify precise measurements, seam placements, and construction details.
Material Sourcing: We select and source the main fabric, linings, and all trims (zippers, buttons, embroidery thread, labels) based on the design requirements.
Pattern Drafting: A master pattern is created from the tech pack, either digitally or by hand. This blueprint is crucial for achieving the intended fit and silhouette.
Timeline: This phase can range from 1-2 weeks for a simple design to 4-8 weeks for complex projects involving unique materials and multiple design iterations.
Phase 2: Prototyping & Fitting
Creating the Prototype (Proto Sample): A first sample is sewn, typically in a similar but less expensive fabric, to test the pattern and construction.
First Fit Session: The prototype is tried on a fit model (or the client). We meticulously assess the fit, comfort, and overall design, marking any necessary adjustments.
Pattern Revisions & Second Sample: The pattern is refined based on the fit notes. A second sample is often produced in the actual final fabric to verify the fit and see how the fabric behaves.
Timeline: Allow 2-4 weeks for this phase. For complex garments or remote clients requiring shipping time, it can extend further. Rushing this stage often leads to fit issues in mass production.
Phase 3: Pre-Production
Final Pattern & Sample Sign-Off: The pattern is finalized after a perfect fit is achieved, and a pre-production sample is approved for bulk manufacturing.
Grading: The master pattern is scaled into the full size range (XS, S, M, L, XL, etc.).
Production Marker Making: Pattern pieces are digitally arranged on the fabric in the most efficient layout to minimize waste.
Line Setup: Sewing lines are organized, and machines are configured for the specific operations required (e.g., coverstitch for knits, special feet for delicate fabrics).
Timeline: This setup typically takes 1-2 weeks.
Phase 4: Production & In-Line QC
Fabric Spreading & Cutting: Fabric is laid out in piles and precisely cut using the graded markers.
Assembly & Sewing: Cut pieces are bundled and move through the assembly line where they are sewn together into finished garments.
In-Line Quality Control: Quality checks are integrated throughout the sewing process to catch issues early.
Embellishment & Finishing: Appliques, prints, or embroidery are added. Finally, garments are pressed, and final touches like buttons are secured.
Timeline: This is the most variable phase. 2-6 weeks is common, heavily dependent on order quantity and complexity.
Phase 5: Final Quality Assurance & Packaging
Final Inspection: Every single garment is thoroughly checked for defects in construction, stitching, and finishing.
Spot Cleaning & Pressing: Any minor flaws are corrected, and garments are pressed for a pristine finish.
Tagging & Labeling: Brand labels, care labels, and hangtags are attached.
Packaging: Garments are folded, poly-bagged, and packed into cartons according to the client's instructions.
Timeline: 1-2 weeks, depending on the order size.
Phase 6: Shipping & Delivery
Shipping Arrangements: The order is prepared for shipment. We can handle logistics or work with your preferred freight forwarder.
Delivery: Goods are shipped via sea (slower, cost-effective) or air (faster, more expensive). Customs clearance is a critical part of this step for international orders.
Timeline: Varies significantly: 2-5 days for air freight, 3-6 weeks for sea freight.
Total Project Timeline (General Estimates):
Basic Project (e.g., simple tee, reprint of existing design): 6–8 weeks
Standard Project (e.g., new design, moderate complexity): 8–12 weeks
Complex Project (e.g., technical outerwear, multiple new designs): 12–20+ weeks
Key Factors That Influence Your Timeline:
Design Complexity: More details mean more time.
Fabric & Trim Lead Times: Sourcing special materials can add weeks.
Number of Fit Samples: Each revision round adds time.
Factory Capacity: Aligning with their production schedule is key.
Order Quantity: Larger runs take longer to produce but are more efficient per unit.
Communication: Prompt feedback from the client keeps the process moving.
Our Recommendation: Start the conversation early. Providing a clear, detailed brief from the outset is the single most effective way to ensure a smooth and efficient process. We will provide you with a detailed, project-specific timeline after our initial consultation.
