Underwear That Feels Like A Second Skin, We Deliver Value, Design, Comfort, Security, And Promise.

Design And Pattern Creation

1. Design Phase

Research: Target users, trends (fabrics/colors), functional needs.

Sketching: Digital/hand-drawn drafts with key structures (cups, straps, closures).

Tech Pack: Size charts, stitch types, material specs, tolerances.

2. Pattern Development

Base Pattern: Body data → panel segmentation (cups, bands).

Methods: Flat/digital drafting (CAD), draping for complex shapes.

Testing: Mock-up fittings → adjust cup fit, strap tension, band stability.

Grading: Scale patterns across sizes; reinforce plus-size panels.

Fabric & Material Selection

Functional Requirements: Determine stretch, breathability, durability, and softness based on garment type (e.g., bras, briefs).

Fabric Types: Prioritize knits (lace, mesh, micromodal) for comfort; elastics (spandex, Lycra®) for support.

Stretch Testing: Ensure 15-30% elasticity for fit retention; verify recovery post-wash.

Comfort Factors: Opt for moisture-wicking, hypoallergenic, and OEKO-TEX® certified fabrics.

Color & Print: Use dye-sub techniques for fade resistance; test colorfastness.

Lining/Trim: Match lining (cotton, bamboo) to skin contact zones; select non-irritating seams/elastic.

Quality Control: Validate shrinkage (<3%), pilling resistance, and wash durability via pre-production testing.

Fabric Cutting Process

Pattern Alignment: Precisely position fabric layers with digital or manual pattern templates.

Layering: Stack fabric evenly to minimize distortion; secure with weights or adhesive.

Cutting: Use sharp rotary blades or laser-guided cutters for accuracy, ensuring clean edges on delicate materials (lace, stretch fabrics).

Notching/Marking: Add small cuts or chalk marks for seam alignment and component matching.

Quality Check: Inspect cut pieces for consistency, flaws, and pattern accuracy.

Sorting: Group cut pieces by size/style for efficient assembly.

Sewing & Assembly Process

Cutting Prep: Precisely align fabric layers; die-cut components (cups, bands, straps).

Seam Construction: Join panels with flatlock/overlock stitches for stretch durability.

Elastic Application: Attach elastic edging using coverstitch/zigzag machines under tension.

Cup Shaping: Sew foam/molded cups into shells; secure with reinforcement stitching.

Closure Integration: Set hooks/eyes or rings/sliders into back bands via bartack reinforcement.

Trim Finishing: Add lace, ribbons, or labels with precision straight stitches.

QC Check: Inspect seam integrity, symmetry, and elastic tension; pressure-test closures.

Embellishments & Branding

Design Mapping – Align embellishments with technical sketches.

Pre-Treatment – Steam/clean fabric for adhesion.

Application

Sew lace/embroidery; heat-transfer rhinestones/foil; print patterns (sublimation/screen).

Labels & Logos

Stitch woven tags into seams; laser-cut care labels.

Apply logos via embroidery, laser etching, or silicone prints.

QC Checks – Stitch density, adhesion peel tests, colorfastness.

Regulatory Compliance – OEKO-TEX®, regional labeling laws.

Finishing and Trimming

Finishing:

Inspect seams, edges, and closures for defects.

Secure loose threads and trim excess fabric.

Press or steam garments to ensure smoothness and shape retention.

Attach labels, tags, or care instructions.

Trimming:

Apply decorative elements (lace, ribbons, bows) using precise stitching.

Reinforce stress points (straps, hooks) for durability.

Final quality check for consistency and compliance with specifications.

Quality Control Inspection

Material Inspection: Verify fabric quality, color consistency, and elasticity.

Stitching Integrity: Check seam strength, uniformity, and absence of loose threads.

Dimensional Accuracy: Confirm measurements (e.g., band, cup, waist) match specifications.

Functionality Test: Ensure hooks, straps, and closures operate smoothly.

Aesthetic Review: Inspect for stains, print alignment, and fabric defects.

Safety Compliance: Test for harmful substances (e.g., AZO dyes, pH levels).

Packaging Check: Validate labeling, hygiene, and correct size tagging.

Packaging Process

Quality Check: Inspect for defects, stitching accuracy, and fabric integrity.

Folding: Neatly fold garments to standard size, ensuring symmetry.

Bagging: Seal in polybags with desiccant (if required) for moisture protection.

Labeling: Attach SKU tags, size labels, care instructions, and compliance info.

Boxing: Arrange packed units in cartons, add layer padding, and seal with inventory details.

Storage/Shipping: Palletize boxes, document batches, and prepare for distribution.