Published: 11/13/2025

If you’ve tried taking a clothing idea from sketch to store shelves, you know this stage can make or break a collection. Garment manufacturing is the bridge between design and delivery, where precision matters as much as creativity.

For new or growing brands, it can feel like a black box filled with acronyms, mismatched quotes, and factory emails that read like a different language. This guide demystifies the process. You’ll learn what actually happens inside a production workflow, what timelines to expect, and how to avoid rookie mistakes that cost time and money.

Quick note: AI Techpacks can auto-create factory-ready tech packs—the document manufacturers rely on for measurements, fabrics, trims, and construction. You don’t need software to follow this guide, but if you want fewer sampling errors and faster communication, it helps.

What Is Garment Manufacturing?

Garment manufacturing is the controlled process of turning a design into a physical product—from finalized specs to finished goods leaving the factory. Think of it as a pipeline of defined stages, each only as strong as the prep that feeds it.

Every phase builds on the last. For example, a missing fabric code, vague stitch note, or incomplete measurement can snowball into costly rework. Your most valuable asset before placing a purchase order is a precise, up-to-date tech pack.

Production can be domestic or overseas. Domestic often means smaller minimums and faster feedback loops. Overseas (Asia, Latin America, Eastern Europe) can offer lower unit costs or specialized machinery. The right choice depends on your budget, category, quality bar, and volumes.

So garment manufacturing isn’t just making clothes. It’s coordinated design validation, production planning, and quality execution. Managed well, it turns vision into a consistent, scalable inventory. Managed poorly, it can stall a launch or sink a season.

Choose Your Production Model: CMT vs. Full-Package (OEM)

Before you sew a single stitch, decide how you’ll work with your factory. Two models cover most scenarios: CMT (Cut–Make–Trim) and Full-Package (OEM). The right choice depends on your experience, bandwidth, and how buttoned-up your specs are.

CMT (Cut–Make–Trim)

With CMT, you provide the materials, trims, patterns, and a complete tech pack. The factory cuts, sews, and finishes to your specifications. You get tight control over inputs and can insist on exact fabrics or certified components.

The trade-off is coordination: you (or your sourcing partner) must order on time, confirm deliveries, and ensure patterns are production-ready. If something’s late or incorrect, the line stalls, and that’s on you.

This model is best when you have sourcing experience, repeat styles, or niche materials that you want to control. The upsides are control, flexibility, and often lower factory markups. But watch out for heavier project management, zero cushion for sourcing mistakes, and a higher bar for tech-pack accuracy.

Full-Package (OEM)

In Full-Package, the factory handles sourcing, patterns, sampling, and bulk production through finishing. You focus on approving designs, fits, and pre-production samples while one partner manages the moving parts.

This convenience usually comes with higher unit costs and, unless you negotiate visibility, less transparency into the exact mills or trim suppliers.

Use Full-Package when you’re launching your first collection, running a lean team, or prioritizing speed to market. The upsides are one point of contact, fewer handoffs, and a lower risk of gaps between vendors. Just be aware of higher per-unit pricing, possible opacity in sourcing, and MOQs that can skew higher.

Hybrid (a practical middle ground)

Many brands mix the two. One common example is the factory sources standard trims and labels while you supply a specialty fabric or proprietary zipper. Spell out who supplies what in the purchase order, include lead-time assumptions, and confirm how substitutions are approved.

A clear split keeps costs predictable and responsibilities clean.

The Garment Manufacturing Process, Step by Step

Once you’ve picked a production model, the workflow moves through a predictable sequence. The goal is to turn a concept into a consistent product while reducing rework.

Step 1: Tech Pack & Specs

Everything starts with a complete tech pack: sketches, measurements, a graded size chart, fabric and trim specs, colorways, stitch types, label artwork, and a bill of materials.

Factories use this to quote, plan, and sample. Vague specs multiply sampling rounds and cost. Use AI Techpacks to generate your tech pack and keep measurements, material codes, and revisions consistent so errors don’t reach the sewing line.

Step 2: Pattern Making & Grading

Pattern makers translate your specs into paper or digital patterns. Once the base size fits correctly, grading scales the pattern across sizes to keep proportions balanced. Good grading prevents odd sleeve lengths, tight necklines, or distorted hems as sizes change.

Step 3: Sampling

Sampling proves the design and construction before you commit to bulk. You’ll typically see three milestones.

• Prototype (Proto): Validates style and construction.
• Fit sample: Dials in measurements and comfort.
• Pre-production (PP) sample: The reference for bulk.

Expect two to three rounds total. Don’t rush approvals; catching a mistake here is far cheaper than fixing it in production.

Step 4: Cutting & Sewing

After PP approval and materials in-house, the fabric is inspected, spread, and cut per the graded markers. Pieces move through sewing lines set up by operation (collar attach, sleeve join, hemming). Clear work instructions and in-line checks matter here; small errors can magnify quickly on an active line.

Step 5: Finishing & Quality Control

Finishing covers thread trimming, button or label application, pressing, folding, and packing. Most factories follow a defined quality level, such as AQL 2.5, using statistical sampling to decide pass/fail. Units that pass are poly-bagged or boxed per your packing instructions and prepared for shipment.

Step 6: Handoff to Logistics

Cartons are sealed, palletized if needed, and transferred to your freight forwarder or the supplier’s logistics partner. This is where Incoterms (for example, FOB, CIF, DDP) define who pays and who carries risk. We’ll break those down shortly.

Key takeaway: The process is linear but interdependent. Strong specs and decisive approvals keep the schedule moving; unclear instructions slow every later step.

Realistic Timelines (Post Tech-Pack Approval)

Even with a great partner, apparel production takes longer than most first-time founders expect. Timelines shift with product complexity, order size, material lead times, and how quickly you review samples. Plan backwards from your launch date and confirm dates with your factory before you announce anything.

Sampling (2–6 weeks)

After you finalize the tech pack, most factories need about 7–10 days for the first prototype. You’ll review, consolidate feedback, and approve the next round. Complex styles, custom prints, or multiple fit rounds can stretch this phase to four to six weeks.

Pro tip: Use a single revision sheet per round. Fragmented feedback slows teams and creates contradictions.

Material Sourcing (often in parallel, 1–3 weeks)

In Full-Package, the factory sources materials while sampling proceeds. Stock fabrics and trims move fast; custom dyes or prints can take 2–3 weeks or more. In CMT, you’re responsible for deliveries. Add at least a week of buffer for supplier slips or customs delays.

Production Slotting (≈1 week)

Once the PP sample is approved and all materials are on site, the factory books your line time. Good factories schedule ahead, so lock your slot early, especially around spring and holiday peaks.

Bulk Production (4–8 weeks)

Most basics run 30–60 days. Simple knits may sit at the low end. Structured jackets, lined dresses, or multi-panel pieces take longer. Ask how many lines (production teams) your order will get; more lines usually mean a faster turn.

QC, Packing, and Prep (≈1 week)

After sewing, garments move through finishing, inspection (often to AQL 2.5), pressing, folding, labeling, and packing. Don’t rush QA here; catching defects before shipment protects margins and reputation.

Transit (varies by mode)

• Domestic ground: ~2–5 days.
• International air: ~5–10 days, including clearance.
• Ocean freight: ~30–45 days port-to-port, plus customs and drayage.

Plan for regional holidays such as Chinese New Year (late Jan–Feb) or Diwali (Oct–Nov). Factory closures and port congestion during these windows can push schedules by weeks.

Key takeaway: Expect 8–14 weeks for most styles. Build contingency into your plan, make approvals fast and clear, and keep a rolling calendar of factory holidays and shipping cutoffs.

MOQs Explained (and How to Start Small)

If you’ve ever been quoted “MOQ 300 pcs/style” or something similar, you’ve hit one of the toughest early hurdles. MOQ means Minimum Order Quantity. It isn’t arbitrary; it’s how factories stay efficient and profitable.

Why Factories Set MOQs

Every new style has fixed setup costs: pattern verification, marker making, machine setup, labor scheduling, and waste planning. Whether a line runs 30 or 300 units, those tasks still happen. Low volumes spread those costs over fewer pieces, so either the unit price rises sharply or the factory asks for a higher minimum.

MOQs also reflect upstream realities.

• Fabric and trim minimums: Mills sell by the roll; zipper and label vendors prefer bulk.
• Line efficiency: Longer, continuous runs keep teams productive and reduce changeovers.

Typical Ranges (ballparks)

These vary by product and region, but here’s a useful lens.

• Basics (tees, hoodies): 100–300 units per style/color
• Denim & outerwear: 200–500 units
• Swim/lingerie: 100–200 units
• Luxury or bespoke ateliers: 25–100 units

Domestic shops (U.S./Canada) often accept lower MOQs at a higher per-unit price, which can still make sense for first runs.

How To Start Small Without Burning Bridges

• Focus your line: Launch with one to three core styles instead of ten. Use color variations to meet fabric minimums without exploding SKUs.
• Choose stock materials: Ask for in-stock fabrics and trims. You avoid mill minimums and shave weeks off sourcing.
• Request a pilot run: Be upfront that you’re testing market fit. Some factories will take 50–100 units if you pay a development fee or accept a slightly higher unit price.
• Go small-batch or local: Regional factories are built for shorter runs and quick feedback loops. Yes, it costs more per unit, but you’ll learn faster and avoid dead inventory.
• Consolidate components: Standardize buttons, labels, or linings across styles to hit supplier minimums sooner.
• Mind your markers: Efficient size and color splits (e.g., S–XL in a tight distribution) reduce fabric waste and keep the cost-per-unit in check at lower volumes.

Pro tip: Treat the first PO as a product and relationship test. Clean tech packs, consolidated feedback, and on-time payments make factories far more flexible the next time you ask for a small run.

Quality Control 101 (AQL, Inspections, Tolerances)

Great design won’t save a collection if quality slips. In apparel, quality control isn’t a final checkpoint; it’s a thread that runs from your first spec to the last packed carton. Whether you’re making 50 or 5,000 units, setting clear standards protects margins and brand trust.

Why QC Matters

Factories juggle many orders at once. Without clear expectations, issues creep in like uneven stitching, skewed prints, off-size measurements, and missing trims. These aren’t minor annoyances. They drive returns, rework, and reputation damage. Bake QC into every step and you’ll ship more consistent products with fewer headaches.

AQL (Acceptable Quality Limit)

Most factories and inspection agencies use AQL based on ISO 2859 sampling. You select a quality level that defines how many defects are acceptable in a sampled lot before the shipment fails.

For everyday apparel, AQL 2.5 is common. Premium products may use AQL 1.5 or 1.0. Stricter levels reduce defect tolerance but can add time and cost. Choose the tightest standard your price point can support, then apply it consistently.

The Inspection Moments That Matter

• Pre-Production (PPI): Verify fabrics, trims, and critical specs before sewing starts. Catching a bad dye lot here saves a re-cut later.
• In-Line (DUPRO): Inspect while the line is running. This is where you stop problems from multiplying.
• Pre-Shipment (PSI) / Final Random (FRI): Sample packed goods against your AQL before they leave the factory. Use this as a release gate for payment and handoff.

You don’t need all three on every order, but at a minimum, use an in-line or pre-shipment inspection on new styles or new factories.

Tolerances

Measurements need tolerances (the acceptable plus/minus range) so teams know what’s “within spec.” For example, chest width 50 cm ± 1.0 cm or sleeve length 62 cm ± 0.5 cm.

Without tolerances, good units get rejected or inconsistent ones slip through. Add tolerances to the size chart in your tech pack and ensure the factory’s QC sheet mirrors them.

Make QC Actionable

• Document it in the PO: State your AQL level, which inspection(s) you’ll use, and the pass/fail criteria.
• Share golden samples: Keep a signed PP sample in your office and require the factory to keep one on the line. All approvals reference these.
• Define defect classes: Minor, major, and critical defects shouldn’t be guesswork. Spell out examples so inspectors align with your standards.
• Close the loop: When issues appear, update the tech pack or work instructions, not just the email thread.

Pro tip: If you’re new, hire a third-party inspector for the first one or two orders. The report doubles as a training tool for you and the factory.

Labels & Compliance for the U.S. Market

If you sell in the U.S., labeling isn’t optional. The FTC and CPSC set rules that apply to everyone—from indie brands to big-box suppliers. Miss them and you risk fines, shipment holds, or forced relabeling.

The good news is that once you set up a clean system, compliance becomes routine.

Four Things Every Garment Must Disclose

1. Fiber content: List fibers in order of predominance (e.g., 95% Cotton, 5% Spandex).
2. Country of origin: Where the garment was made (cut and sewn), not where the fabric came from.
3. Manufacturer or RN: You can use your company name or an FTC-issued RN (Registered Identification Number).
4. Care instructions: Provide at least one safe cleaning method and any relevant temperature or cycle guidance.

These requirements stem from the Textile and Wool Acts and the Care Labeling Rule. If you use care symbols, include text somewhere (label or hang tag) so customers don’t guess.

Placement and Permanence

Labels should be durable and easy to find at the point of sale. For tops, place the identity and fiber/COO label at the center of the back neck. For bottoms, inside the waistband or side seam is good.

Care info can sit on a separate label. If a garment has detachable parts (e.g., a liner), each piece may need its own label. Heat transfers are fine if they remain legible for the life of the garment.

Care Labeling Rule, in Practice

Give customers instructions they can follow at home or with a cleaner without damaging the item. At minimum, specify a safe method (machine wash, hand wash, or dry clean). Add what matters: water temperature, cycle type, drying, ironing, and don’ts such as “Do not bleach” or “Do not iron decoration.”

If a process is required for safe cleaning, say so (e.g, “Dry clean, petroleum solvent only”).

Children’s Apparel: CPSIA Extras

For products sized for 12 and under, you’ll need tracking labels (batch or date codes) and compliance certificates covering applicable standards (lead content, flammability, small parts where relevant). Keep test reports and certificates organized; customs can request them.

Make Compliance Foolproof

• Centralize specs: Keep label copy, RN, care icons/text, and placement notes in your tech pack.
• Lock artwork: Provide print-ready files for size tabs, brand labels, and care labels so factories don’t “recreate” art.
• Sample the label: Approve label content and placement on the PP sample and photograph it for the record.
• Audit occasionally: Spot-check production to ensure label text, RN, and COO match the PO and style.

Pro tip: Build a one-page “Labeling Matrix” that lists each style, material variations, and the exact label set it should receive. Share it with the factory’s trim room and QC team. It prevents mix-ups and speeds inspections.

Shipping Terms (FOB, CIF, DDP)

When cartons are sealed, your last big decision is how risk and cost move from the factory to you. Incoterms (International Commercial Terms) spell this out. You don’t need all 11. For most apparel shipments, learn these three and you’ll avoid surprises.

FOB — Free On Board

Under FOB, the supplier’s responsibility ends once goods are loaded on the vessel at the origin port. From that point, you own the freight, insurance, risk, and customs.

This is good for brands with a freight forwarder or import experience. You control carriers, routes, and costs; pricing is transparent. But there’s a trade-off: you manage more steps and handle any post-departure hiccups.

CIF — Cost, Insurance, and Freight

With CIF, the supplier pays for ocean freight and basic insurance to the destination port. You take over after arrival: customs, duties, local delivery.

This is good for teams that want fewer moving parts but still manage import clearance. And there’s less coordination on the origin-side freight. Trade-offs are limited visibility into rates and schedules; supplier markups are common.

DDP — Delivered Duty Paid

DDP is the all-in option. The supplier handles everything—freight, insurance, customs, duties, and delivery to your door for a single price.

It’s good for new importers or lean teams, and offers simplicity and predictable invoices. The trade-offs are a higher total cost and less control over how customs is handled.

Picking the Right Term

• Cost visibility: If you need to compare landed costs across styles or seasons, FOB gives cleaner numbers.
• Team capacity: If you don’t have a forwarder or import broker, DDP removes the heavy lifting.
• Cash flow: CIF and DDP can feel easier, but watch for embedded margins. Ask for a freight cost breakdown before you agree.
• Country risks and holidays: Ports back up around peak seasons and holidays. Whatever term you choose, build buffer time into your delivery promise.

Put your chosen Incoterm, named place (e.g., “FOB Shanghai”), and who books insurance in writing on the PO. Don’t rely on phrases like “shipping included.” That could mean CIF, DDP, or even EXW (factory door pickup), which pushes almost everything to you.

Pro tip: Even on DDP, request copies of the commercial invoice, packing list, bill of lading/airway bill, and duty/tax proof. You’ll need them for landed-cost analysis and future planning.

Conclusion

Garment manufacturing is a sequence. When your specs are clear, approvals are decisive, and roles are defined, the process moves. Most delays trace back to fuzzy tech packs, late materials, or slow feedback. Fix those three and you’ll feel the schedule click into place.

If you want to reduce sampling errors and keep all details synced, you can use AI Techpacks to generate your tech packs automatically. It will keep your measurements, BOMs, and revisions organized so factories can execute faster.