When it comes to men’s underwear, there are many different styles and options to choose from. But ever wonder how they’re made? In this comprehensive guide, we’ll take you through the entire process of how men’s underwear is made.
From the fabrics used to the various steps involved in the manufacturing process, we’ll cover them all so whether you’re just curious about how it works or looking for some new ideas for your own business, this content may help you learn more about the details.
1. Commonly used fabrics for lingerie and their composition
● Organic cotton
● Recycled nylon
● Merino wool
● Modal
● Bamboo fiber
● Recycled polyester
● Spandex
① Cotton is the most popular fabric for underwear. It is soft, absorbent and comfortable. Cotton is made from the cotton plant, which is native to tropical and subtropical regions around the world. The seeds of the plant are used to make this fabric.
②Nylon is another popular fabric for underwear. It is strong and durable. Nylon is made from a synthetic polymer called polyamide.
③ Merino wool is a type of wool that is made from the fleece of Merino sheep. This fabric is soft, breathable and has natural anti-odor properties. It is also a relatively high-end fabric material, this fabric production panties, the unit price will also be much higher than other ordinary fabric panties.
④ Modal is a type of rayon. It is made from the cellulose of the beech tree. One beech tree can normally produce 1800 pieces of underwear modal fabric.
⑤ Bamboo fiber is made from the pulp of the bamboo plant. It is soft, absorbent, and antibacterial.
⑥Polyester is a synthetic fabric, made from petroleum. Many purchasers who advocate environmental protection nowadays will ask for recycled polyester. Compared with ordinary polyester fabric, recycled polyester fabric has the following 5 advantages.
-It uses less energy and water to produce.
-It produces less pollution.
-It is made from post-consumer waste, so it diverts waste out of landfills.
-It is as strong and durable as regular polyester.
-It is made from recycled PET bottles and recycles non-biodegradable materials.
⑦Spandex is an elastic fabric used in many types of clothing, including underwear. It is made from a synthetic polymer called polyurethane.
The above 7 are the types of fabrics that we often use in the production process.
According to the experience of Ystar factory, the normal fabrics are not used alone in the actual production, they will be blended with other fabrics to achieve the actual needed effect.
2. The different stages of production – from fabric cutting to packaging
Now that we have introduced the different types of fabrics used to make underwear, let’s take a look at the manufacturing process.
The first step is the selection of the fabric.
Once the fabric has been selected, it will be dyed and surface printed accordingly.
Dyeing is a complex process, and the process of dyeing different qualities of cloth varies from cotton, polyester-cotton, nylon, polyester, chemical fiber products, blended products, etc. Some of them can be dyed by rolling and dyeing, while others have to be dyed by high temperature and high pressure, some are dyed only once, and some have to be colored several times. The specific dyeing process should be judged according to the fabric and the actual color needed.
The second step is fabric cutting and printing, these two steps will have flexible adjustment according to the different printing patterns.
Digital printing steps: first printing and then laser cutting machine to cut the fabric
The specific operation process is as follows.
● Layout on the computer
● Punching paper according to the layout
● The picture on the paper is laminated to the fabric by machine
● The fabric is laser cut
● The cut fabric is sorted and sent to the sewing workshop for sewing
Automatic fabric cutting machine:
the fabric is cut first, and then the part of the fabric to be printed is sent to the printing workshop for printing according to the printing requirements
The machine arranges the fabric layer by layer
(There is a limit to the cutting thickness of the fabric during the actual operation, too much thickness will easily lead to a slight displacement of the fabric in the lower layer during the cutting process, which will lead to errors when cutting)
Cut the whole fabric according to the computer layout
The cut fabric is sorted and the parts that need printing are sent to the printing department for processing, and then all the fabrics are sent to the sewing workshop for sewing after processing.
This step can also be done by printing the fabric first and then cutting the fabric.
Different fabrics are also suitable for different types of printing. For example, in actual production, the polyester material used in sports underwear is currently only suitable for digital printing, which is one of the most popular printing methods in the market because of its rich colors and realistic effects.
Put the picture, introduce the automatic fabric cutting machine and laser fabric cutting machine
Cotton, modal, bamboo fiber, wool material underwear is not suitable for complex color full-page printing.
After the fabric is cut according to the desired shape, the next step is to sew the various parts of the fabric together. The machine that performs these sewing operations is called a sewing machine. Currently there are also many sewing automation machines, such as the waistband on panties.
Ystar is currently using an automatic waistband sewing machine, which can automatically cut and sew, and one worker looks after multiple machines, greatly improving productivity and reducing labor costs.
After the fabric is sewn together, the next step is to add any embellishments that may be needed. This may include things like buttons, bows or stickers.
Finally, the newly made panties will go through multiple inspection processes and then be packaged accordingly for shipping
3. Stitching process used for sewing the waistband, shoulder straps and other parts of the fabric
The sewing process used for different parts is different and requires different sewing equipment.
Processing process of men’s underwear.
Front: first over locking the edge, and then the surface press the bundle
Back file: first over locking the edge, then four needles and six threads coverstitch (overlock)
Bottom file: first locking the edge and then three needles and five threads(flatlock)
Side: four needles and six threads (panties without side design details can ignore this step)
Leg opening: double needle, foot opening double needle can car
Upper rubber root: three stitches
press label: single thread stitching
Equipment used for hem locking: hem locking machine
Equipment used for pressing the bundle: bundling machine
Equipment used for three needles and five threads:
Equipment used for four needles and six threads.
Equipment used for cutting the foot opening: Cantering machine
Equipment used for upper rubber root.
Equipment used for pressing labels.
4. Various surface treatments that can be applied to underwear
-Anti-bacterial
-Deodorant
-Humidity absorption and perspiration wicking
-UV protection
These are just some of the finishes that can be applied to lingerie. Each one has a different purpose and can be used to create a unique product. For example, fabrics with sun protection need to have a UV protection finish.
5. Brand and wash label and fabric connection
The brand label is normally located in the middle of the waistband of the underwear, there are generally two ways to deal with it: one is to directly design the logo into the waistband when the belt is made; the second is to do a brand of woven label, and then later sew the woven label to the belt. (Put reference chart)
Washing label is an important part of the product, it is a legal requirement in most countries. The content of the wash label varies from country to country, but there are some common elements: fiber content, washing instructions, country of origin, and size.
Washing labels are also available in two finishes.
1. Printing, where the label content is printed directly on the middle of the back side of the underwear by means of silk-screening or watermarking. (Put reference chart)
2. Cloth label sewn on the side of the panties. (Put reference picture)
6 Quality control measures in the manufacturing process
-Inspection at the factory. All materials must be inspected upon arrival at the factory. This includes checking for defects, damage and impurities.
-In-process inspection. This is done at all stages of the manufacturing process to ensure that the product meets all quality standards.
-Final inspection. This is an inspection that is performed before the product is packaged to confirm that the product meets the customer’s quality requirements before it leaves the factory.
Ystar currently uses the AQL 2.5 quality inspection system which is above the industry standard. We have an additional 10 QC’s who are responsible for random inspection of products produced online and promptly address minor issues that are overlooked by production staff during actual production to ensure that all products we produce meet our customers’ quality requirements.
7. concluding paragraphs
This is a quick overview of how underwear is made. If you would like to know more about the specific fabrics used and the handling methods, please contact us. We will go over every step of the process from fabric cutting to quality control. If you’re interested in learning about some of the leading brands in the industry, we have that covered as well. So, let’s get started!