How Are T-Shirts Made in Factories？

T-shirts are a wardrobe essential found in closets worldwide. But have you ever wondered how a simple T-shirt goes from a piece of fabric to a finished product in factories? The T-shirt manufacturing process involves multiple steps, including fabric selection, cutting, sewing, printing, and finishing. In modern factories, this process combines advanced machinery, skilled labor, and quality checks to produce millions of T-shirts efficiently.

In this guide, we’ll explore the detailed T-shirt manufacturing process in factories, from cotton harvesting to the final product. Whether you’re a consumer, designer, or business owner, understanding how T-shirts are made in factories can help you appreciate the effort involved and choose reliable manufacturers for custom needs. Let’s dive into the step-by-step T-shirt production process, from raw materials to the final product.

What Is the T-Shirt Manufacturing Process?

The T-shirt manufacturing process involves a series of carefully managed steps that transform cotton or blended fabric into finished garments ready for retail. It combines traditional craftsmanship with modern textile machinery, ensuring precision, comfort, and durability.

At Newasia Garment Co., Ltd., we follow a vertically integrated production system, meaning we control every stage — from material sourcing to garment finishing — to guarantee consistent quality and on-time delivery.

What are the key steps in the production process of a standard T-shirt?

I often get asked about the T-shirt process. It sounds simple, but every step demands care. Each phase decides overall quality. This drives me to focus on detailed planning and tracking.

A standard T-shirt goes through several phases: design, pattern making, fabric selection, cutting, sewing, and quality checks. Each stage affects fit, finish, and final appeal. Understanding these phases helps me avoid costly mistakes.

Step-by-Step: How T-Shirts Are Made in Factories

1. Step 1: Choosing the Fabric for the T-Shirt

The foundation of how T-shirts are made in factories starts with selecting the right fabric. This choice affects everything from comfort and durability to how well the T-shirt holds prints. Factories source large rolls of fabric, often in bulk, to meet production demands.

Common fabrics include cotton, polyester, and blends, each tailored for specific uses. For instance, cotton is popular for its breathability, while polyester excels in sportswear due to moisture-wicking properties.

Fabric Type	Features	Best For
100% Cotton	Soft, breathable, absorbs ink well	Everyday wear, screen printing
Cotton-Poly Blend	Less shrinkage, durable, soft texture	Fashion T-shirts, DTG printing
100% Polyester	Moisture-wicking, lightweight	Sportswear, sublimation printing
Tri-Blend (Cotton/Poly/Rayon)	Soft, vintage feel, stretchable	Premium, fashion-focused T-shirts

Once selected, the fabric is treated, dyed, and pre-shrunk in factories to prepare it for cutting, ensuring consistency across batches.

✅ At Newasia Garment Co.,Ltd., we this dual approach of selective sourcing and proprietary fabric development ensures perfect material solutions for each client’s unique vision and target market to ensure every fabric meets global safety and sustainability standards.

Step 2: Creating the T-Shirt Pattern

In factories, a precise pattern acts as the blueprint for every T-shirt. This step ensures uniformity in sizing and fit, crucial for mass production.

Designers use specialized software like Gerber or Optitex to draft digital patterns. These are then graded for various sizes (e.g., S to XXL) and printed or laser-projected onto fabric stacks.

A well-crafted pattern minimizes waste and guarantees that the final T-shirt aligns perfectly during assembly.

Step 3: Cutting the Fabric

With the pattern ready, factories move to cutting—where large fabric rolls are transformed into individual panels like fronts, backs, and sleeves.

Automated cutting machines, such as laser or die cutters, handle multiple layers at once for efficiency. Key steps include:

• Spreading: Fabric is layered evenly on long tables.
• Cutting: Machines slice according to the pattern.
• Sorting & Labeling: Pieces are organized by size and part.

This factory process reduces errors and speeds up production, often handling thousands of pieces per hour.

Step 4: Sewing and Stitching the T-Shirt

Sewing brings the cut pieces together in factories using high-speed industrial machines. Workers assemble the body, attach sleeves, and finish the neckline.

Common stitching techniques ensure durability:

Stitch Type	Purpose
Overlock Stitch	Prevents fabric edges from fraying
Flatlock Stitch	Creates a smooth, seamless look
Coverstitch	Strengthens hems and sleeve edges

These methods help T-shirts withstand repeated wear and washing, a hallmark of factory-quality production.

Step 5: Printing and Embellishment

Customization happens here, where blank T-shirts get designs via printing or embroidery in specialized factory sections.

Popular methods include:

Printing Method	Best For	Features
Screen Printing	Bulk orders, simple designs	Durable, cost-effective for large runs
DTG (Direct-to-Garment)	Small orders, detailed prints	High-quality, full-color designs
Heat Transfer (DTF, Vinyl)	Small-batch customization	Great for sports jerseys, logos
Sublimation	Polyester shirts, all-over prints	Vibrant, permanent prints

Factories choose methods based on order size and fabric, ensuring designs last through washes.

Step 6: Washing & Finishing

To achieve a soft handfeel and stable sizing, T-shirts are washed using:

• Enzyme Wash – for smoothness and softness
• Silicone Wash – for a luxurious finish
• Stone Wash – for vintage looks
• Ozone / Eco Wash – for sustainable finishing

Our factory is equipped with eco-friendly washing machines and wastewater treatment systems that comply with international environmental standards.

Step 7: Quality Control and Inspection

No T-shirt leaves the factory without rigorous checks. Inspectors examine for defects using automated scanners and manual reviews.

Checks cover:

• Stitching accuracy (no loose threads).
• Print alignment.
• Fabric integrity (no holes or inconsistencies).
• Size verification.

This step upholds factory standards, reducing returns and building brand trust.

Step 8: Packaging and Shipping

Finalized T-shirts are folded, tagged, and packaged in factories for distribution.

Options include:

• Poly Bags: Affordable and protective.
• Eco-Friendly Packaging: Sustainable materials.
• Branded Boxes: For premium lines.

Shipping varies: sea freight for bulk, air for urgency.

Simplified T-Shirt Production Flow Chart (Text Version)

Fabric Sourcing → Fabric Relaxation → Pattern Making → Fabric Cutting →
Printing/Embroidery → Sewing → Washing/Finishing → Quality Control →
Ironing/Folding → Packaging → Shipment

This streamlined process ensures efficiency, precision, and sustainability from start to finish.

From Factory to You, Cut Out the Middleman

• Say goodbye to the waiting game with direct communication.
• Work directly with the team to create custom products to your exact needs.
• No middlemen means no markup—just direct, cost-effective pricing.
• No guesswork—get a clear view of your costs and progress.

We can provide

We are a clothing manufacturing group that focuses on producing high-quality clothing and adhering to the concepts of environmental protection and sustainable development.

How are T-shirts made step by step in the factory?

I remember feeling lost the first time I visited a factory. The process seemed chaotic. Then I saw the structured flow. Understanding this eased my worries and helped me estimate timelines. Each station adds a piece of the puzzle.

Factories follow a sequence: fabric inspection, cutting, bundling, sewing, and finishing. Each step demands consistent checks. Workers align patterns, attach collars, and handle seams with precision. This approach ensures fit and quality remain steady.

From cutting to sewing, what are the steps of a T-shirt on the assembly line?

I see a stack of fabric layers on large tables. Cutting machines trim patterns precisely. Then workers bundle matching pieces. Sewing teams attach sleeves, neckbands, and hems. I watch them handle collars carefully. Every stitch matters because small misalignments affect fit.

How do printing, embroidery, and washing processes affect the finished T-shirt?

I like to add logos or graphics. Printing or embroidery comes after sewing. These processes can affect stretch and drape. Then washing sets color and removes loose threads. I monitor temperature and chemicals to avoid shrinkage. This final step locks in the T-shirt’s look.

How long does it take for a T-shirt to be packaged and shipped from the factory?

Lead times often stress me out. I must manage shipping and promotions. My advice is to plan ahead. A well-structured timeline avoids surprises. Efficiency depends on teamwork, raw material readiness, and swift communication.

Production usually takes one to three weeks, depending on order size. Good coordination with suppliers and freight services speeds everything up. A systematic approach cuts delays and ensures timely delivery.

Sustainable Manufacturing at Newasia Garment Co., Ltd.

We’re not just making clothes — we’re building a greener future.
Our sustainability initiatives include:

• BSCI and ISO14001 certified production
• GRS-certified recycled fabrics
• OEKO-TEX® compliant dyes and inks
• Laser cutting & ozone washing for reduced water use
• Energy-efficient equipment and waste recycling programs

🌏 Every T-shirt we produce aligns with global sustainability goals.

Why Choose Newasia Garment Co., Ltd.?

• 39+ Years of Apparel Manufacturing Experience
• 140 Production Lines & 12,000 Skilled Workers
• Daily Output: 100,000+ Pieces
• MOQ: 100 pcs/style – ideal for startups & brands
• Full OEM/ODM Customization
• Worldwide Shipping (USA, UK, EU, Australia, Middle East)
• Clients Include: GAP, American Eagle, Levi’s, Lee, Uniqlo

We transform your ideas into premium, retail-ready garments — on time, every time.

FAQ – How Are T-Shirts Made in Factories?

Q1: What materials are used to make T-shirts?
Mostly cotton, polyester, organic cotton, and spandex blends depending on comfort, breathability, and stretch needs.

Q2: How long does it take to manufacture T-shirts?
From sampling to delivery — typically 15–30 days, depending on order size and customization.

Q3: Can I create my own custom T-shirt line?
Yes! We provide full OEM/ODM services — from design and pattern creation to branding, packaging, and delivery.

Q4: Do you produce sustainable T-shirts?
Absolutely. We offer organic cotton, bamboo fiber, and recycled polyester options with eco-washing techniques.

Q5: What is your minimum order quantity (MOQ)?
Our MOQ starts from 100 pcs per style, perfect for startups and growing brands.

How Long Does It Take to Manufacture a T-Shirt?

Factory timelines depend on scale and customization, but here’s a typical breakdown:

Production Step	Time Required
Fabric Selection & Prepping	1–3 days
Pattern Creation & Cutting	2–5 days
Sewing & Stitching	3–7 days
Printing & Customization	2–6 days
Quality Control & Packaging	1–3 days
Total Production Time	7–20 days

Bulk orders might extend to 2–4 weeks, while automated factories can shorten this.

Clothing Manufacturer – Customized Clothing Solutions For Every Concept

We deliver fully integrated, end-to-end apparel manufacturing that seamlessly blends design intent with technical execution. Our in-house fabric R&D lab develops proprietary textiles—from advanced performance blends to sustainable cottons and recycled polymers—ensuring material innovation aligns with your brand’s aesthetic and functional needs.

Through precision pattern engineering and fabric mapping, we create tailored through relaxed silhouettes optimized for drape, movement, and consistency. Each collection is supported by comprehensive development services: tech pack preparation, size grading, garment dyeing, custom washes, and specialty finishes. With full control over the entire supply chain—from yarn to final garment—we guarantee quality, scalability, and brand integrity across every piece we produce.

Trusted Certificates：

Trusted by Global Clients

OUR PROCESS

New to T-Shirt Customization? We Make It Easy

You don’t need to be an expert — just tell us what you want to print, and we’ll guide you to the right technique. From bold screen prints to delicate embroidery, we help you choose what fits best based on your design, budget, and fabric.

Printing Techniques

Dye & Wash Processes

How Do We Guarantee the Quality

Our quality assurance begins with designing and planning, then continues through every step of the production and post-production inspections. Delivery is not an ending. We still offer money-back guarantee for quality issues. 

Comprehensive Clothing Brand Customization Solutions

Choose Newasia Garment Co.,Ltd. The Real Veteran for Startup Clothing Brands

Start Your Custom T-Shirt Line Today!

Looking to create your own premium T-shirt collection?
Partner with Newasia Garment Co., Ltd. — where precision meets passion.

📩 Send us your tech pack or design idea today!
We’ll turn it into a high-quality, market-ready product.

👉 Contact Newasia Garment Co., Ltd.
Your Trusted Global Clothing Manufacturer.

Read more: How Are T-Shirts Made in Factories？

• Design to Garment: NewAsia’s End – to – End OEM/ODM Service
• OEM vs. ODM: Which is right for your business?
• How Much Does It Cost to Manufacture a T-Shirt ? Full Breakdown & Factors
• How Are T-Shirts Made in Factories？
• How Many T-Shirt Companies Are There? Global Overview & Industry Insights