Custom t-shirt manufacturing begins with a clear techpack — a technical specification document that captures every detail of the garment: fabric composition, GSM, colour(s), artwork positioning, label and tagging instructions, size chart, construction details (seam type, stitch density, hem style), and packaging requirements. The more precise the techpack, the fewer revision rounds are needed and the faster the manufacturer can deliver an on-specification first sample. Many brands underestimate the techpack stage and then spend weeks iterating on samples because critical details were left ambiguous.
Once a sample is approved, production moves through the following stages: fabric procurement and inspection, spreading and cutting, sewing and assembly, screen printing or embroidery (if applicable), finishing (trimming threads, ironing, folding), quality inspection, labelling, and finally packing for shipment. A reputable manufacturer will share AQL (Acceptance Quality Level) inspection reports and allow independent third-party inspections before shipment. Lead times from sample approval to shipment typically range from 45–75 days for a fresh order, shorter for repeat styles. Planning your product calendar around these lead times — including buffer for customs clearance — is essential for avoiding stock-outs.