Custom Underwear: Your Step-by-Step Guide
At our factory, we make custom underwear production simple and transparent. Follow these five steps to create your perfect product—whether it’s seamless activewear, bonded lingerie, or classic cotton briefs.
Step 1: Choose Your Construction Method
The first decision is how your underwear will be made. Each technique suits different styles and budgets:
Best for: Activewear, shapewear, invisible underwear.
How it’s made: Knitted in one piece using circular knitting machines (Santoni, Sangiacomo).
Advantages: No side seams, ultra-lightweight, reduces irritation.
Limitations: Slightly higher cost; limited to stretch fabrics.
2. Bonded (Glued Seams)
Best for: Luxury lingerie, no-show underwear.
How it’s made: Fabrics fused with medical-grade adhesives (Bemis, Hotmelt).
Advantages: Smooth edges, lightweight, no chafing.
Limitations: Not ideal for heavy fabrics like thick cotton.
3. Traditional Stitched (Sewn)
Best for: Everyday cotton underwear, retro styles, reinforced designs.
How it’s made: Double-needle stitching, bar-tack reinforcements.
Advantages: Most durable, works with all fabrics.
Limitations: Visible seams, slightly heavier.
Step 2: Select Your Fabric
| Fabric | Best For | Key Benefits |
|---|---|---|
| Organic Cotton | Everyday briefs, boxers | Breathable, hypoallergenic |
| Recycled Nylon | Sporty styles, seamless | Stretchy, eco-friendly |
| Recycled Polyester | Affordable activewear | Moisture-wicking, durable |
| Bamboo Viscose | Soft underwear, eco-brands | Antibacterial, silky feel |
| Modal/Tencel | Premium seamless | Ultra-soft, biodegradable |
Sustainability Note:
OEKO-TEX® or GOTS-certified options available.
Recycled fabrics add ~10-15% to cost but appeal to eco-conscious buyers.
Step 3: Determine Sizing
We support standard and extended sizing:
Basic Sizing (Included in MOQ)
→Men’s: S–XXL (waist 28–40 inches).
→Women’s: XS–XL (hip 32–44 inches).
Extended Sizing (Additional Cost)
→Men’s: Up to 4XL (waist 44+ inches).
→Women’s: Up to 3X (hip 48+ inches).
Fit Guide:
Provide your size chart, or we’ll use ASTM/EN standards.
Custom grading available for unique fits (e.g., maternity, tall).
Step 4: Choose Colors
Pick from solid colors, heathers, or prints:
Standard Colors (Pantone-matched): Black, white, nude, navy, etc. (MOQ: 500+ per color).
Custom Colors: Submit Pantone codes (+15% fee for color-matching).
Prints: Sublimation or all-over print (MOQ: 1,000+).
Color Rules:
More colors = higher MOQ (e.g., 3 colors → 1,500 pieces total).
Dyed-to-match elastics/threads available.
Finally, send us your design so we can provide pricing and lead time:
Option 1: Email Tech Packs/Drawings
Include: Flat sketches, measurements, fabric specs.
We’ll respond within 48 hours with a quote.
Option 2: Send a Physical Sample
Mail us an existing product to replicate.
We’ll reverse-engineer it and suggest improvements.
What’s Next?
Sample Phase (7–10 days): We’ll make a prototype for approval.
Production (25–35 days): Bulk manufacturing begins.
Quality Check + Shipping: AQL 2.5 inspection before delivery.
Ready to Start?
Download our tech pack template [here].
Email designs to [camille@gyknit.com.cn].
Questions? Chat live with our design team.
