1. The Tech Pack: The Blueprint
Before a single thread is cut, the design must be digitized. The Tech Pack (Technical Packet) is the instruction manual for the factory. It contains every detail required to build the garment.
- Flat Sketches: Detailed line drawings showing front, back, and side views.
- Measurements: Spec sheets with P2P (Point to Point) measurements for every size (XS to 4XL).
- Construction Details: Stitch types, seam allowances, and labeling positions.
- Bill of Materials (BOM): A list of every fabric, trim, zipper, and thread needed.
2. Pattern Making & Grading
The pattern is the skeleton of the garment. Master pattern makers translate the 2D Tech Pack into 3D shapes.
- Base Size Pattern: Usually created in Size M (Men's) or Size L (Women's) first.
- Grading: The mathematical process of resizing the pattern up and down to create XS, S, XL, etc., while maintaining the intended fit and proportions.
- Marker Making: Arranging the pattern pieces on the fabric digitally to minimize waste.
3. The Proto Sample (First Draft)
This is the first physical version of your design. It is usually made with substitute fabrics (similar to but not exactly the final fabric) to test the design viability and construction methods quickly.
| Focus Area | Checklist |
|---|---|
| Design Aesthetics | Does the print look right? Are colors correct? |
| Style Accuracy | Does the collar shape match the sketch? Pockets in the right place? |
| Construction | Are seams straight? Is the stitching type correct? |
| Basic Sizing | Is the general proportion correct (too long/short)? |
4. The Fit Sample (Movement Testing)
Once the design is locked, we create the Fit Sample using the actual production fabric (e.g., moisture-wicking polyester with spandex). This stage is crucial for athletic wear.
- Live Model Test: The garment is worn by an athlete who performs the sport's specific movements (throwing, sprinting, stretching).
- Range of Motion: Checking for riding up, restriction in shoulders, or tightness in the quads.
- Adjustments: Issues found here lead to pattern tweaks (e.g., adding 1cm to the armhole depth or lengthening the torso).
5. The Golden Sample (Pre-Production)
This is the "Master Copy." The Golden Sample is 100% identical to what will be shipped in bulk. It serves as the standard for Quality Control during production.
- Final Materials: Correct fabric, zippers, threads, and labels.
- Final Branding: Correct logo size, placement, and embroidery density.
- Approval: You must physically sign off on this sample. Once approved, no changes can be made without halting production and incurring costs.
Sample Approval Checklist
- ✔ Tech pack measurements match physical sample
- ✔ Fabric hand-feel and weight are correct
- ✔ Color is accurate (compare to Pantone swatches)
- ➕ Print/Logo placement is centered and aligned
- ➕ Stitching quality is high (no loose threads)
- ➕ Zippers and buttons function smoothly
- ✔ Label and Care instruction content is verified
- ✔ Athletic range of motion is tested
- ✔ Packaging requirements are confirmed
- ✔ Signed "Golden Sample" returned to factory
Start Your Prototype Today
Ready to see your design come to life? Dhalay International offers a streamlined sampling process to get your team from concept to the field faster.
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