The clothing manufacturing process involves multiple steps, from design to finished product, requiring precision and expertise. In this writing, Thygesen Textile Vietnam will explain each stage in detail.
1. Pre-production process
Before mass production, fashion brands go through key pre-production steps like design development, material sourcing, sample making, and production planning. This helps reduce errors, control costs, and improve efficiency.
Design development
The first step is to develop the initial concept through sketches or mood boards. This helps define the style and theme of the collection.
Next, create detailed design sketches and tech packs. Tech packs include specifications like measurements, fabrics, and trims, which guide the manufacturer in producing the garments accurately. Then, send the designs and tech packs to the manufacturer for review and discussion.
Materials selection
Materials selection is a critical step in the design process, as it directly impacts the quality, durability, and functionality of the finished product. In this phase, you need to carefully choose the right fabrics, trims, and components that align with your design vision while meeting the performance requirements of the garment.
If you’re new to fabric selection, partnering with an experienced manufacturer can make the process easier. With extensive experience across various product categories and a wide network of suppliers both locally and internationally, Thygesen is here to guide you in selecting the best fabrics.
Sample making
This process includes steps such as: adjusting patterns, testing fabric performance, refining stitching, perfecting construction,…all to ensure the garment stays true to the original idea while being optimized for mass production.
To make samples match brand expectations, manufacturers work closely with brands through multiple sample rounds, typically 2-3 rounds. Brands provide feedback on fit, fabric feel, and construction details based on the given tech pack specifications or visual assessment of overall balance.
For brands working remotely, Thygesen offers professional online sample fitting meetings or direct sample shipping when needed, ensuring thorough evaluation. Necessary adjustments are made promptly based on feedback, guaranteeing both quality and scalability in bulk manufacturing.
2. Clothing production process
From fabric inspection to cutting, sewing, and finishing, every step in mass production is carefully managed to ensure quality, efficiency, and consistency.
Fabric inspection
The initial touch on the material sets the foundation for a flawless production process. Fabric inspection goes beyond detecting defects, it’s about understanding the fabric’s characteristics, such as weight, stretch, and durability, to ensure it meets the design requirements.
This step allows for seamless coordination between teams, early identification of potential challenges, and the development of the best production plan.
Cutting and sewing
Once fabrics pass inspection, they move to precision cutting, where advanced automation and expert pattern design ensure efficiency and accuracy. Each piece is meticulously prepared for seamless assembly, setting the foundation for high-quality garment construction.
During the sewing stage, skilled workers carefully stitch the fabric pieces together, transforming flat materials into fully shaped garments. This step is crucial in bringing the brand’s vision to life while maintaining structural integrity and design precision.
At the Thygesen factory, every production line is optimized with LEAN principles. In the cutting stage, smart layout planning reduces fabric waste, while in sewing, standardized workflows and balanced line setups minimize idle time and ensure smooth production. Our skilled workers are carefully selected and trained for each product, maintaining both speed and quality.
Quality checking
After the sewing process, each garment undergoes a meticulous inspection to ensure the highest quality. Surface texture, stitching accuracy, seam strength, and measurements are carefully checked to guarantee the right fit and durability. For example, with sports bras, quality control checks include reinforced stitching at stress points, fabric stretch and recovery, moisture-wicking performance, and secure fit of elastic bands and closures.
Thygesen implements 100% in-line inspection, 100% final or AQL inspection, and offers third-party quality control upon request, ensuring every product meets brand expectations.
Finishing
The final touches are applied to ensure each garment meets the highest standards. This includes removing loose threads, trimming edges, and attaching labels or tags. Every piece is carefully prepared for a polished and professional look before packaging.
3. Post-garment manufacturing process
Once production is complete, garments go through pressing and folding, careful packaging, and efficient shipping to ensure they arrive in perfect condition.
Pressing and folding
At this stage, garments are carefully pressed and folded to ensure they maintain their intended shape and appearance before packaging. Industrial steam irons or heat presses are used to smooth out wrinkles and remove any creases from the sewing or quality control process, ensuring a polished look. Once pressed, each garment is folded according to brand standards or customer specifications.
Packaging
The final step is packaging, where each garment is carefully packed to ensure the products are protected from dust, moisture, or damage during storage and transportation. Depending on brand preferences, packaging can include biodegradable materials or recycled options to minimize environmental impact. Once packed, the cartons are securely sealed and prepared for shipment, guaranteeing they arrive at their destination in perfect condition.
Shipping
Once packaging is complete, the next step is arranging bulk shipping via air or sea, depending on the brand’s requirements. Thygesen ensures efficient logistics management, offering various shipping terms such as FOB (Free on Board) and DDP (Delivered Duty Paid) to meet different needs. Every shipment is carefully coordinated to guarantee timely delivery while maintaining product integrity throughout transit.
In conclusion, the clothing manufacturing process involves multiple critical steps, from fabric inspection, cutting, and sewing to finishing, packaging, and shipping. Each stage plays a vital role in ensuring the final product meets quality and design expectations.
As an ethical apparel manufacturer, Thygesen carefully manages every step with precision and responsibility, delivering high-quality garments that align with your brand’s vision. Learn more at thygesenapparel.com or contact us at [email protected].
