How Hoodies Are Manufactured

Fleece rolls arrive under loom tension. Left un-relaxed, the finished garment will shrink 5–8% in the first wash. Rolls are spread flat and rested 24 hours in a climate-controlled room (20°C / 65% RH) before cutting so the yarn recovers its natural loft.

CAD-graded markers are printed and laid over 30–50 ply spread stacks. A straight-knife or automated cutter follows the marker. Grainline is locked to the roll direction — cross-grain panels bias-twist after the first wash.

• Marker efficiency: 82%+ on 280gsm French terry.
• Bundle tags — every cut piece is numbered so a size-M front panel never joins an L sleeve.
• Fusible interlining is cut for the placket and hood facing on premium builds.

Screen print and DTF run on flat front panels before assembly — a curved shoulder is impossible to register. Embroidery can go pre- or post-assembly; chest hits usually pre, sleeve hits usually post.

Shoulder seams close first on a 4-thread overlock. Sleeve caps set into the armhole. Side seams and sleeve inseams close in one continuous run. Kangaroo pocket is set-in or jetted into the front panel before shoulder close.

• 4-thread overlock — main seams, 4.0 SPI (stitches per inch).
• Cover-stitch — hem and pocket top-edge for a flat, stretchy finish.
• Bar-tacks — pocket corners, hood eyelet reinforcement, drawcord ends.

2-panel hoods have a centre seam running crown to nape; 3-panel hoods add a gusset for a rounder drape and better shape retention. Metal or plastic eyelets punch through both hood layers, and a flat drawcord (6–8mm cotton or polyester) threads through the channel.

Hood attaches to the neckline with a bound seam covered by a 1cm neck tape (self-fabric or contrast twill). Ribbed cuffs and hem — 2x2 or 2x1 rib with 3–5% elastane — attach with a cover-stitch. Zip-ups get their YKK zipper installed at this stage.

Every hoodie goes through a thread-trim station and a steam form-press. Main label, size label and care label (already sewn in earlier) are checked. Hangtags attach with a plastic barb or a cotton string.

Pre-shipment AQL 2.5 inspection: measurement audit against tech pack tolerances, colour match to lab dip, seam strength spot-check, zipper cycle, no needle contamination. Passed units fold onto a card, drop into a polybag, and pack into export cartons (12–24 pcs per carton depending on GSM).