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The sportswear production process moves from brief and development through material selection, pattern and fit, artwork, cutting and decoration, sewing and finishing, quality checks and finally labels, packing and dispatch. For a custom sublimated jersey, Voyager Sportswear cuts the polyester fabric into panels, prints the artwork on sublimation transfer paper, transfers it to the panels with heat and then sews them. The buyer approves materials, fit and artwork along the way, and some stages overlap rather than following a fixed order.
In Turkey, Voyager Sportswear runs integrated sportswear production in house, from pattern making and sampling to cutting, printing, sewing, finishing and quality control. This guide explains the production decisions and links to the detailed resources. The minimum order is 100 pieces per style, and we confirm the exact scope and schedule for each project.
Follow the work and its approval points
| Stage | What is settled | Buyer input or decision | Detailed guide |
|---|---|---|---|
| Brief and development | Garment purpose, design and open questions | Reference, approximate quantity, destination/date and support needed | Tech pack |
| Materials | Composition, structure, weight, finish and availability | Priorities and approval of the proposed material | Fabric selection |
| Pattern and fit | Panel shapes, measurements, construction and grading | Sample comments and size-range approval | Fit and grading |
| Artwork | Files, colours, dimensions and numbering | Approved design and size breakdown versions | Artwork preparation |
| Cutting and decoration | Garment pieces and the chosen printing or application route | Approved inputs and any critical placement requirements | Sublimation sequence |
| Sewing and finishing | Assembly, edges, trims and closures | Confirmed construction reference | Seams and construction |
| Quality checks | Goods assessed against agreed requirements | Inspection scope and response to findings | Inspection planning |
| Labels and packing | Product identification, sets, cartons and records | Market and receiving requirements | Packing specification |
Some tasks overlap and some development decisions require another sample. The table is a map of the work, not a fixed sequence of separately charged stages.
Select fabric for the product
Composition alone does not determine performance. A polyester mesh and a smooth polyester interlock can differ in coverage, surface and print appearance. Compare structure, weight, stretch, recovery and feel against the intended fit and use.
Check colours and decoration on the proposed material itself. For close-fitting garments, a swatch cannot fully show movement or coverage. If a quantified performance claim or a certified-content claim is required, agree the evidence before using it in product wording.
How the custom sublimation route works
For a custom sublimated jersey, the usual Voyager Sportswear route is:
- Confirm the design, pattern, material and the size and artwork references.
- Cut the polyester fabric into garment panels.
- Print the artwork onto sublimation transfer paper.
- Transfer the design from paper to the panels using heat.
- Sew the printed panels into the garment.
Club crests, sponsor logos and numbers can be built into the panel artwork if they are approved in time. A repeating pattern can instead be transferred onto the fabric by the metre before cutting and sewing. A large graphic alone does not mean the fabric has to be printed on the roll.
DTF, other heat transfers and embroidery are separate decoration options, and the stage at which they are applied depends on the material, access and placement. Check that the method suits the fabric and gives the appearance you want. A sponsor logo that arrives late cannot always be applied to garments that are already finished. The method comparison helps with that decision.
Approve what the sample actually establishes
Agree the purpose of each sample and any provisional materials in it. A fit sample, a colour strike-off and a complete garment sample answer different questions. Record the approved reference, the specification versions and any corrections still outstanding, with how each will be checked.
Where grading matters, look at selected sizes beyond the base size. On numbered orders, the numbers and size totals have to match the approved size breakdown. The sampling guide sets out a practical approval process.
Checks during the run and before dispatch
Decide which checks matter for material identity, dimensions, seams, print, colour, labels and numbering. A sampled inspection supports a decision about a lot, but it does not verify every garment or every number. If the order needs checks on every piece, tests or an independent inspection, agree them as well.
If a difference is found, identify the goods affected, investigate against the reference and agree the corrective work and how it will be verified. Keep changes separate from the original approval so that production does not mix incompatible revisions.
Questions and answers
What are the main stages of custom sportswear production?
Custom sportswear production moves through brief and development, material selection, pattern and fit, artwork, cutting and decoration, sewing and finishing, quality checks, then labels and packing. At each stage the buyer provides something, such as a reference, sample comments, an inspection scope or an approved design or size breakdown. Some stages overlap and some decisions need another sample, so the stages are a map rather than a fixed sequence.
Does fabric composition decide how a sportswear garment performs?
Fabric composition alone does not decide how a sportswear garment performs. A polyester mesh and a smooth polyester interlock can differ in coverage, surface and print appearance, so compare structure, weight, stretch, recovery and feel against the intended fit and use. For close-fitting garments, a swatch cannot fully show movement or coverage. Where a quantified performance or certified-content claim is needed, agree the evidence before using the claim in product wording.
Does a sampled quality inspection check every sportswear garment?
A sampled quality inspection does not check every sportswear garment or number: it supports a decision about the lot as a whole. Define the checks that matter, such as material identity, dimensions, seams, print, colour, labels and numbering, and agree separately any checks on every piece, tests or independent inspection the order needs. If a difference is found, identify the affected goods, investigate against the reference and agree corrective work.
Plan from the ready date to receipt
Confirm labels and packing early enough for them to be sourced and applied. A matched set needs sizes for each component, and a retail order may need barcode mapping. Ask which packing and documentation are included.
The date the goods are ready and the date they arrive are different milestones. Each project needs its own plan, allowing for material availability, development, review, production, checks and transport. The schedule guide helps you work backwards from the date you need to receive the goods.
To start, send your product idea or reference with the approximate quantity, any artwork you have and the decisions you would like help with. A complete tech pack is useful if you have one, but you do not need one for a first discussion.