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9 Key Points to Consider When Producing Flexible Workwear and Uniforms
High-stretch fabrics have been widely used in workwear and uniforms in recent years due to their superior elasticity, comfort, and form retention. However, due to the unique process requirements in cutting, sewing, and processing of high elastic fabrics, the garment production process is more complicated and elaborate than that of ordinary fabrics. This article will introduce in detail the production process of high elasticity fabrics, from fabric selection to finished product inspection, each step needs to be highly concerned to ensure the final quality of the garment.
- Fabric Selection
High elasticity fabrics mainly include spandex, Lycra, etc., which have high elasticity and high recovery. The choice of fabric directly affects the comfort, wearability, and aesthetics of the garment. To produce high-quality garments, fabrics should meet the following basic requirements:
1.1 Elasticity and Recovery
High elasticity fabrics should not only have high elasticity but also be able to recover quickly after repeated stretching. To ensure this property, fabrics with a certain proportion of spandex content are usually chosen.
1.2 Breathability and moisture absorption
Although elasticity is important, breathability and moisture absorption are also key indicators of comfort. Especially for sportswear, which requires fast perspiration, it is especially important to choose high-elasticity fabrics with excellent performance.
1.3 Durability
The durability of a garment depends on the abrasion and pilling resistance of the fabric. Durability is a very important consideration for high-elastic garments worn for frequent activities.
- Fabric Pretreatment
High-elastic fabrics are usually subjected to a series of pre-treatments before entering the garment manufacturing process to ensure that the fabric behaves consistently during the subsequent processing.
2.1 Shrinkage
All high elastic fabrics are shrink-treated before they are cut and sewn. This helps to prevent distortion and shrinkage of the finished product during the wearing and washing process.
2.2 Ironing and preshaping
By ironing and pre-shaping, the fiber structure of the high elastic fabric can be made more stable, which is convenient for subsequent cutting and sewing.
2.3 Inspection and trimming
The fabrics are thoroughly inspected to eliminate any quality problems such as color differences and blemishes. This step can avoid problems in all production stages of the garment.
- Core design and sampling
Detailed design work and sampling are required before the formal production of garments. The nature of high-stretch fabrics requires that special consideration be given to elasticity and comfort. This includes sizing, cutting, bonding, etc.
3.1 The design stage
Designers need to carry out structural design and style design according to the characteristics of the fabric and the needs of customers. The special characteristics of high elasticity fabrics dictate that the design needs to consider the changes of clothing under dynamic, including how to ensure the elasticity and form stability of the fabric.
3.2 Pattern making and sample making
After the design is completed, pattern-making and sample-making are carried out. In the process of pattern making, special attention should be paid to the setting of the seam allowance, and the sample garment should be tried on and adjusted in detail to ensure comfort and aesthetics.
3.3 Try on and adjustment
Further, adjust the design and pattern by trying on the sample garments to ensure the comfort and suitability of the garments in actual wearing.
- Cutting
High-elasticity fabrics are difficult to cut because they are not easy to fix due to their elasticity. Specialized tools and techniques are used at the cutting stage to ensure that the size of the cut pieces is accurate.
4.1 Equipment selection
Use automatic cutting machines or specialized cutting equipment for high elastic fabrics. These equipment usually have high-precision control systems that can effectively reduce fabric movement and deformation. Meanwhile, using specialized cutting table and automatic fabric spreading machine can help to ensure that the fabric is laid flat.
4.2 Pattern processing
For high-elasticity fabrics, it is necessary to reserve an appropriate amount of shrinkage in the pattern design to adapt to the stretch requirements of the garment in the process of wearing. A certain amount of seam allowance must be reserved between each piece to ensure that the pieces will be matched smoothly during the sewing process.
4.3 Checking the cut pieces
After the cutting is completed, check the cut pieces one by one to see whether there is any size error, or missing or redundant pieces. Ensure that each piece is accurate to avoid problems in subsequent processes.
- Sewing
Sewing is the most important part of garment production, especially for high-elasticity fabrics, the choice of sewing process and operation methods directly affect the quality of the garment.
5.1 Choose the right needle and thread
High elasticity fabrics need special needles and threads, commonly used such as elastic threads, which are rigid and strong, but also have a certain degree of ductility, which can meet the elasticity requirements of high elasticity fabrics when they are subjected to force.
5.2 Knowledge and skills
When sewing high-elasticity fabrics, skilled workers need to master certain skills, such as how to control the sewing tension, to avoid fabric deformation caused by over-tightening the seam. At the same time, familiarise themselves with the operation of different sewing machines and choose the correct sewing needle size to suit different thicknesses of high-elasticity fabrics.
5.3 Specialised sewing machines
Use specialized elastic sewing machines such as flat-bed sewing machines, lockstitch machines, and 3-thread lathes. These machines have high sewing speed and elasticity control capability, which can improve productivity and garment quality.
- Assembly and Sewing Techniques
In the assembly and sewing process of high-elastic fabric garments, special attention needs to be paid to the treatment of seam joints to ensure the quality of each seam point.
6.1 Sewing joint treatment
To avoid the abruptness of the seam joints, the combination of flatlock and lockstitch can be used, and attention should be paid to the smooth transition of the seam lines at the same time. For some critical parts such as shoulders and cuffs, reinforcement threads can be added to improve the durability of the garment.
6.2 Elasticised joints and elasticized seams
If the fabric is particularly elastic, elastic joints can be used with elastic seams so that the sewn joints can extend synchronously when under stress, avoiding joint breakage caused by broken connecting seams.
- Post-processing
After the garment has been sewn, a series of post-treatment procedures are required to improve the overall quality and aesthetics of the garment.
7.1 Quality control and trimming
Carry out a detailed inspection of each garment to ensure that there are no color differences, damage, loose threads, or other problems. Repair and rework any problems found promptly.
7.2 Ironing and shaping
The garments made of high elasticity fabrics are easy to deform during the sewing process, and ironing can make the lines of the garments smoother and the overall appearance more beautiful.
7.3 Packaging and storage
The garments will be packed after quality inspection and ironing. The garments made of high elasticity fabrics need special attention in the process of packing and storing to prevent pressure and deformation, to maintain the shape and elasticity of the garments.
- Finished product inspection
After all garments are completed, a finished product inspection is required. Finished product inspection includes size check, function check, and appearance check.
8.1 Size inspection
Use professional measuring tools to check the size of each garment to make sure that each size meets the design requirements and that there is no size error due to elastic shrinkage.
8.2 Function check
Check the stretch performance, comfort, and durability of the garments by wearing a test. Garments made of high-elasticity fabrics are required to maintain their elasticity and shape even after repeated stretching wearing and washing.
8.3 Appearance Inspection
Check the appearance of the garments, including surface finish, seam flatness, and color consistency. Ensure that each garment meets good appearance standards.
- Garment logistics and sales
After the finished product passes the inspection, it starts to enter the logistics process and finally goes to the market. Garments made of high-elasticity fabrics need to be kept in good condition during logistics and storage.
9.1 Packaging for Logistics
Use appropriate packaging materials, such as pressure- and moisture-resistant boxes or bags, to ensure that garments are not damaged during transport. Also, moisture-proof packaging materials can be added to the package to keep the garments dry.
9.2 Storage conditions
Storage of high elasticity fabrics needs to be kept dry and ventilated, avoiding direct sunlight and humid environments to prevent weakening of fabric elasticity and performance.
9.3 Sales Strategy
In terms of sales strategy, it is necessary to fully demonstrate the advantages of high elasticity fabric garments to the market, including comfort, elasticity, and versatility, to attract more customers’ attention and purchase.
Summary
The production process of high-elasticity fabric garments is crucial in every step from fabric selection to finished product inspection. In the face of the unique characteristics of high elasticity fabrics, it is necessary to ensure that each garment meets high standards of quality, comfort, and aesthetics through a scientific and rigorous process. In the face of changing market demand and an increasingly competitive environment, apparel companies need to continue to innovate and optimize the production process, to produce higher quality high-elastic fabric garments. Through the detailed explanation in this article, we hope that it can provide some valuable references for the relevant practitioners engaged in the production of high-elasticity fabric garments, and further promote healthy