Ordering custom hoodies sounds simple, but the steps between design and delivery can be confusing if you’re not familiar with how factories operate.
The custom hoodie production process includes design finalization, fabric sourcing, sampling, bulk production, and quality control before shipping.
Understanding each stage helps avoid delays, miscommunication, and unexpected costs. Whether you’re ordering 50 or 5,000 pieces, the process follows the same core structure.
Table of Contents
- What happens during the design stage?
- How is the fabric selected and prepared?
- What is included in the sampling process?
- How does bulk production actually work?
- What happens before hoodies are shipped out?
- Conclusion
What happens during the design stage?
The design stage often feels abstract, but it’s the foundation for every hoodie that comes off the line.
At this stage, technical requirements, customization details, and visual preferences are confirmed to create a clear production roadmap.
Design details to confirm
A factory can’t start production until all hoodie specs are finalized. These usually include:
| Design Element | Notes or Examples |
|---|---|
| Style reference | Pullover / zip-up / oversized hoodie |
| Fabric preference | 100% cotton, cotton-poly blend, fleece, etc. |
| Color selection | Based on Pantone or swatches |
| Print or embroidery | Logo size, location, method |
| Fit or measurements | Custom size chart or standard size? |
| Label & packaging | Neck label, care label, hang tags |
Factories often provide a basic tech pack template if buyers don’t have one. Visuals (e.g., mockups, sketches) help minimize interpretation errors.
How is the fabric selected and prepared?
Fabric is the heart of a hoodie. It affects comfort, shape, durability, and price.
Once designs are set, factories source fabrics according to the agreed specifications and prepare them for production.
Key fabric selection steps
1. Fabric sourcing
Factories may pull from their stock fabrics or source new rolls from partner mills based on client requirements. Sampling is often done to check texture and stretch.
2. Color confirmation
Most custom colors are dyed according to Pantone codes. A lab dip (small fabric swatch) is created and must be approved by the buyer before bulk dyeing begins.
3. Fabric testing (optional)
Some clients require shrinkage, colorfastness, or stretch recovery testing—especially for performance or premium lines.
| Step | Responsibility | Timeline |
|---|---|---|
| Select fabric composition | Client/factory | 1–2 days |
| Approve lab dip | Client | 2–5 days |
| Place fabric order | Factory | 5–10 days (avg.) |
Factories often pre-order 5–10% extra fabric to account for waste or defects during cutting.
What is included in the sampling process?
Before producing 500+ hoodies, it’s critical to check one finished piece for correctness.
The sampling phase involves creating a prototype hoodie to verify material, sizing, print placement, and construction quality.
Common sample types
| Type of Sample | Purpose |
|---|---|
| Fit sample | Confirms pattern and sizing |
| Pre-production (PP) | Final version used to approve mass prod. |
| Salesman sample | For photo shoots or buyer showcases |
Depending on complexity, one or more sample rounds may be required.
Buyers should review:
- Stitch quality and seam placement
- Print sharpness and alignment
- Fabric weight and softness
- Overall fit when worn
Revisions should be documented clearly. Sample approval is typically confirmed in writing or by email.
How does bulk production actually work?
Bulk production transforms fabric and specs into finished hoodies in large volumes.
Factories cut, sew, print, inspect, and pack each hoodie in coordinated assembly line steps, often across several departments.
Hoodie production steps
1. Cutting
Fabric is layered and cut based on digital markers. Proper cutting ensures size consistency.
2. Printing or embroidery
Logos and designs are applied after cutting, before assembly. Screen printing, DTG, and embroidery all have different setup needs.
3. Sewing
Pieces are sewn together in order—hood, body, sleeves, hem, etc. Flatlock stitching may be used for activewear.
4. Trimming and finishing
Loose threads are trimmed, and garments are steamed or pressed to improve presentation.
5. Packing
Hoodies are folded, bagged, and boxed based on client specs. Bulk or individual packaging is both possible.
| Department | Task Description |
|---|---|
| Cutting room | Cut based on CAD files and lay plans |
| Printing dept. | Logo application and cure process |
| Sewing line | Sequential hoodie assembly |
| QC station | In-line and post-line inspections |
| Packing team | Barcode tagging, folding, boxing |
Depending on order size, production may take from 10 to 30 working days after sample approval.
What happens before hoodies are shipped out?
Even after production finishes, multiple checks are required before shipment begins.
The final stage includes quality inspection, packing verification, and logistics coordination based on client instructions.
Final inspection
Common checkpoints:
- Size matches
- Print location consistency
- Fabric damage (holes, dye stains, skipped stitches)
- Packaging matches PO (SKU, labels, quantity)
Some buyers hire third-party inspection teams like SGS or BV. Others rely on the factory’s internal QC report with videos/photos.
Logistics preparation
- Inner and master carton size defined
- Shipping mark placement confirmed
- Export documentation prepared (invoice, packing list, etc.)
If shipping via sea, booking space and coordinating pickup may take 3–7 days. Air freight is faster but more expensive.
Conclusion
Producing custom hoodies in bulk involves much more than just sending a design file. Knowing what happens at each step improves communication, reduces delays, and protects quality.
Frequently Asked Questions (FAQ)
How long does it take to produce custom hoodies?
The typical production time for custom hoodies ranges from 25 to 40 days. This includes sampling, fabric sourcing, bulk production, inspection, and packing. Lead time depends on order size and sample approval speed.
What fabrics are best for custom hoodies?
Common fabrics include cotton fleece (for warmth), French terry (for lighter comfort), cotton-poly blends (for durability), and recycled polyester (for sustainable collections). Fabric choice depends on your brand style and customer needs.
What is included in a hoodie sample?
A sample includes the confirmed fabric, logo application (print or embroidery), stitching method, sizing, and construction details. It represents the final product and must be approved before bulk production begins.
