For cycling clubs and teams kitting a whole roster

Cycling Team Kit Manufacturing — Cut to the Club’s Own Chart

A club kit is one look across every size and every rider. We draft the jersey and the short to the club’s own chart, lay the artwork out for panel sublimation, and prove a made-up kit before the roster order is committed.

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OEKO-TEX 100BSCIGRS

What a club kit starts at

Four figures that hold for a roster order, before a metre of cloth is committed.

Minimum order

100 pcs per colour

Prototype sample

7–10 working days

Bulk production

7–15 working days

Final inspection

AQL 2.5

A club order is measured in colourways rather than single pieces — the minimum and the windows do not change for a team.

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Where a club order slips

Five Ways a Roster Kit Goes Wrong, and the Fix for Each

Each tab is a way a club kit breaks down. Open it for the cost, our answer, and the kit the club ends up with. Dotted terms explain themselves on hover.

The problem

One club’s kit arrives in colours that do not match

  • A jersey and a short cut in separate runs can read as two different club colours.
  • Each reorder is dyed and printed from scratch against last season’s garment.
  • Two orders placed a season apart are only compared when both reach the start line.

What it costs if left

  • A club photographed in mismatched kit looks unsponsored.
  • Members reordering a full set receive halves that do not agree.
  • Merchandise sells on the look, and the look is the first thing to go.

Our answer

  • Sublimation dyes the pattern into the cloth, so a reorder is printed from the same file.
  • Jersey, short and finishing travel as a single order.
  • Printed panels are dyed from one file, so the second order matches the first.

The gain

  • A roster that reads as one club from any angle on the course.
  • Reorders that hold the club’s colours season after season.
  • Photographs that show one club, not two.

Who it stalls

  • Riders who cannot wear a mismatched kit to a race.
  • Sponsors whose brand sits on a colour that has shifted.
  • Members who joined on the strength of the kit and then waited for a match.

The problem

The pad sits where the saddle is not

  • A generic chamois is placed by pattern rather than under the rider’s sit bones.
  • Bottoms graded on a retail chart move the insert as the size changes.
  • Riding position varies, and a pad set for one posture is wrong for the next.

What it costs if left

  • Under load a short that rides up ends a long day painfully.
  • Saddle complaints trace back to a pad that was never positioned for the rider.
  • Long days end in saddle sores a better-placed insert would have prevented.

Our answer

  • The short is patterned so the insert lands under the sit bones in every size.
  • Pad depth and placement are set for the club’s own riding style and distance.
  • Insert depth is chosen for the club’s distances, from a short run to a century.

The gain

  • A short a rider can wear for the whole stage.
  • Support that holds where the body needs it, size after size.
  • Comfort that holds from the first kilometre to the last.

Who it stalls

  • Anyone finishing a long day on a pad that shifted under them.
  • Club captains fielding complaints they cannot fix on the road.
  • Long-distance riders calling for a better insert.

The problem

The kit lands after the race it was ordered for

  • Late orders are sent by sea to meet a price the committee agreed.
  • Sampling and bulk run as separate waits, so the first kit arrives after the race.
  • Race dates do not move, and a kit that misses one is late for the season.

What it costs if left

  • A team lines up in last season’s kit for the races it ordered for.
  • New clubs wait out a season before the first strip ships.
  • Slipping orders send riders to a rival kit in the meantime.

Our answer

  • Artwork and the size chart are locked before the first run, so sampling is not repeated.
  • A made-up kit is approved on the club’s chart, then the roster is cut against it.
  • Sample and chart are confirmed together, so the run is not restarted.

The gain

  • Kit arriving for the season it was designed for.
  • One approval point between the brief and the whole roster.
  • Dates the club can promise its members.

Who it stalls

  • Races where a team has no kit in the new design.
  • Committees who promised the members a date.
  • Supporters who ordered a kit they cannot wear to the first race.

The problem

Every rider wears a different size and none is a stock one

  • Roster bodies come in shapes no single retail chart covers.
  • Sizes are right only when they are drafted to the club’s own measurements.
  • Riders who train hard are not shaped like the sample the chart was built on.

What it costs if left

  • Riders ride down a size because that is all that was cut.
  • Exchanges inside a club order eat the committee’s budget.
  • Wrong sizes leave a rider with nothing to wear on the day.

Our answer

  • The numbers the club supplies set the pattern and its grading.
  • One file keeps the sizes apart, so a repeat is cut to the same shape.
  • Trial sizes are cut from the club chart before the full roster is ordered.

The gain

  • Each member gets a size cut to their own measurement.
  • Anyone joining later is fitted from the file that already exists.
  • Every rider fitted, from the smallest to the largest.

Who it stalls

  • New members ordering a size that does not match the club’s chart.
  • The kit secretary holding a list of exchanges after every drop.
  • Kit secretaries managing a drawer of unused sizes.

The problem

Print cracks along the seams it was cut through

  • Artwork printed across a whole panel breaks where the panel is cut and sewn.
  • Logos placed without the seam allowance land half off the sleeve.
  • Sponsor logos stretched across a panel seam are the first thing the club hears about.

What it costs if left

  • Patterns bleed into a seam and read as a defect on the finished kit.
  • Sponsor marks that should sit square arrive skewed by the cut.
  • Designs that must cross a seam get redrawn by hand at the maker.

Our answer

  • Design is laid out for the panel sublimation step, so seams fall between printed panels.
  • Marks are placed against the cut line, so a logo stays whole on the finished piece.
  • Tests on the chosen cloth show how far a print stretches before it cracks.

The gain

  • Patterns that run clean across the whole jersey.
  • Sponsor marks that sit square on every rider’s kit.
  • Colours that survive the wash after the race.

Who it stalls

  • Clubs whose crest splits across a shoulder seam.
  • Designers whose artwork was never intended to cross a cut.
  • Brands whose name peels off in the first wash.

The build, held on file

One Chart, One Design, One Roster

Our solution

A club kit starts with the members it has to fit and the design it has to carry. We turn the club’s own numbers into the pattern, prepare the artwork for the print method, and hold both on file — so a later season is a repeat of an approved standard rather than a fresh build. The pad, the collars and the finishing are set at the same time, so the whole kit is confirmed on one approved piece.

What you gain

  • Every size drawn from the numbers the members sent.
  • Colours that survive a reorder without drifting.
  • A build the later drop is measured against.
  • One locked design that a later reorder can be printed from.
  • Sizes and colours proved on a trial before the season.
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Building a club kit

Six Steps from the Club’s Chart to a Repeatable Kit

Each step is named before the next begins, so a roster order is never discovered mid-run.

  1. Club size chart

    The club sends its own measurements, and the chart they form becomes the pattern the whole roster is cut to.

  2. Artwork laid out for panels

    The print is set between the cut lines, so a pattern is never split by a stitch.

  3. Full-width sublimation before cutting

    Print is dyed into the cloth across the full width, then the panels are cut from it.

  4. Made-up kit signed off

    Fit, colour and mark placement are checked on a sewn kit before the full order runs.

  5. Sizes confirmed across the roster

    Trial sizes come back from the club before the whole order is cut to the chart.

  6. Reorders from the same file

    Chart and artwork are held, so the next drop is printed and cut to the approved standard.

What a kit order covers

Six Things Handled before the Club’s Kit Ships

A club kit touches the chart, the artwork, the print, the pad, the sizes and the shipment. Here they are kept in one order rather than split across suppliers.

Club size chart

Numbers the roster supplies become the pattern the whole order is cut to.

Artwork for panels

The design is placed against the cut lines so no print is split by a stitch.

Sublimation

Colour is dyed into the cloth across the full width before cutting.

Pad and finishing

Pad and finishing are set in the pattern, on the approved sample.

Trial sizes

Trial pieces come back from the club before the full order is cut.

Packing and freight

Pack and shipment are quoted together at the brief.

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Why build a club kit here

Why a Roster Kit Builds Well Here

The chart, the laid-out print and a signed-off kit hold a club order together through a season.

One chart runs the whole roster

The club’s measurements are written once and reused for every size, every rider and every reorder.

One chart

Print laid out before it is cut

Artwork is placed against the cut lines in the panel step, so a design is not broken by a seam.

Laid for panels

A made-up kit signed off first

Fit, colour and mark placement are approved on a sewn kit before the roster order is committed.

Signed off first

Pad set for your riding, not a default

Insert depth and placement are set in the pattern for the distance the club actually rides.

Set in the pattern

Reorders from the same file

The chart and the artwork are held, so the next drop is printed and cut to the approved standard.

Same file

Small clubs are the normal case

A first season for a new club is what the minimum is set for, not an exception to a bulk schedule.

Built for clubs

From brief to first kit

A Chart and a Design In, a Kit Out

The club sends its own numbers and artwork; a made-up kit comes back first.

What you send

  • A club size chart, or a roster of measurements to build one from.
  • Design files, a sketch or a previous jersey.
  • Numbers per size, the pad you want and the sponsor marks.
  • The first race the kit has to reach.

What comes back

  • A pattern drawn from the club chart, graded across the roster.
  • A made-up kit on the approved cloth, signed off before the order.
  • One dated quote covering the cloth, the pad and the terms.
  • The full order printed, cut, inspected and packed to the standard.
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Read this before you send the roster

Kits We Build

A kit with a design of its own and a roster to fit is the kind we build.

This is a fit

  • A club, team or shop kitting a whole roster rather than one rider.
  • Designs that can be laid out for panel sublimation.
  • Numbers you already hold for your members, or a set we can build one from.
  • A season of kit that has to match across a jersey and a short.
  • Sponsor marks that have to sit square on the sleeve.

This is not a fit

  • A single jersey bought as a one-off.
  • A single continuous print that cannot be broken by a cut.
  • Riders each left to guess a size with no shared chart.
  • Briefs that expect a full-colour kit without sublimation.
  • Stock kit relabelled as club kit with no design of your own.

Where the kit detail lives

The Pages behind the Club Kit

This page sets out the club order. The two links carry the cycling build and the print method.

Cycling Clothing Manufacturers

Jerseys, shorts and the pad build, drafted to the buyer’s own chart for clubs and teams.

Sublimation Printing

The print method that dyes colour into the fibre, so a club design is reordered without a reprint.

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Client cases

Three Client Runs, and What Each Came Back With

Each card is one client: the brief they brought, the work behind it, and the numbers the run produced.

Case 01

Nova Hospitality

UK hotel group

80 → 950Units/month in 16 months
1.8%Defect rate
4.8★Avg. customer rating

The challenge

  • This UK hotel group rolled out front-of-house uniforms across seven locations without a fixed colour standard.
  • Restock batches arrived with noticeable shade variation, and embroidered crests were placed inconsistently.
  • Male and female sizing lacked uniformity, leaving mismatched stock unusable across rotating staff shifts.

The solution

  • We established a permanent fabric and colour reference for the full uniform programme.
  • A single master tech pack defined precise embroidery placement and role-based grading for reception, housekeeping and F&B teams.
  • Each fabric lot was cross-checked against the approved swatch before production. AQL 2.5 inspection and batch archives supported seamless future replenishments.

The result

  • Monthly output scaled from 80 to 950 units across 5 uniform SKUs, maintaining a 1.8% defect rate.
  • All reorder batches matched the original brand colour.
  • Uniform consistency was maintained site-wide, and replenishment orders were reliably delivered on schedule.
Case 02

Prime Logistics

European warehouse & transport brand

+34%Margin per unit after consolidation
36%Repeat purchase rate
10/10Site rollouts delivered on time

The challenge

  • Their polos, hi-vis jackets and work trousers were sourced from three disconnected suppliers.
  • Fabric performance was inconsistent; garments degraded rapidly after repeated industrial laundering.
  • Embroidery placement varied, and each new warehouse rollout required full spec renegotiation.

The solution

  • Every uniform style was consolidated into one managed production programme.
  • Hardwearing, laundry-stable fabrics were selected to withstand heavy shift use.
  • Brand markings were locked to fixed measured coordinates. A dedicated programme manager oversaw specs, sampling, QC and end delivery.

The result

  • Consolidation to a single manufacturer lifted per-unit margins by 34%.
  • Reliable garment durability drove repeat replenishment rates to 36%.
  • Ten separate site deployments were completed on time over two years, with no hold-ups for new warehouse launches.
Case 03

Apex Facilities

MENA facilities management company

3 → 14SKUs in 22 months
28+Countries shipped DDP
0Quality returns in 2025

The challenge

  • Shirts, softshell jackets and cargo trousers were produced by different factories, creating batch-to-batch colour mismatch.
  • Global shipments carried unplanned customs costs and inconsistent packaging quality.
  • No single vendor took end-to-end accountability for quality as their product range expanded.

The solution

  • Cut & sew, screen print, embroidery, custom packaging and DDP logistics were integrated into one workflow.
  • A master specification document locked fabric, colour, sizing and brand mark positions for every SKU.
  • Every batch was inspected against the unified standard, with import duties pre-calculated and included within all DDP pricing.

The result

  • Their uniform portfolio expanded from 3 to 14 SKUs across 22 months.
  • DDP deliveries to 28+ countries arrived with no unexpected customs charges.
  • Zero quality returns were recorded in 2025 for all field staff uniforms.

Questions

Frequently Asked Questions About Cycling Team Kits

01Can you work from the club’s own size chart?

Yes — the pattern is built from the members’ own numbers, and it is kept for the next season.

02Will a reorder match the kit we sold last season?

A second order is cut and printed to the kit the club already approved, so it matches without a new design.

03Can the pad be positioned for our riders?

The pad is positioned in the pattern, so it supports the rider at every size.

04What is the sample fee?

A prototype is $80–150 per style, credited back at a bulk order of 500+ pcs and itemised on the quote.

05How are freight and duty handled?

Freight is quoted to the destination country as DDP, DAP or DPU, with the duty position written on the same quote as the goods.

06How long does the freight take?

Air runs 5–7 days and sea 30–45, both timed from the point the consignment leaves.

07Do you make the matching gilet and arm warmers?

Layers are cut from the same chart and dye file as the jersey, so the set stays one design.

08Can we add a sponsor halfway through the season?

Sponsor marks are placed from the design file, so a late logo is printed on the next club reorder.

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Kit the club in one drop

Kit the Roster in One Order.

Send the club’s size chart, the design and the roster. What comes back is a made-up kit on your own chart, dated before the season it is meant for.

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