How the Cut-and-Sew Process Works

Fabric Selection and Pattern Design

The process begins with selecting the fabric and creating garment patterns that define the shape, fit, and construction.

Cutting Fabric Panels

Fabric is cut into specific panels based on the pattern, ensuring consistency across all garments in the production run.

Sewing and Assembly

The cut panels are stitched together to form the garment, including seams, collars, sleeves, and hems.

Benefits of Cut-and-Sew Apparel

Complete Design Control

Cut-and-sew allows full customisation of garment shape, sizing, and construction details.

Unique Fit and Style

Brands can create distinctive silhouettes, including boxy, oversized, or tailored fits not available in standard blanks.

Seamless Print Integration

Designs can be planned around seams and panels, enabling creative layouts and all-over printing effects.

Printing and Decoration Options

Pre-Print Fabric Panels

Artwork can be printed on fabric before cutting and sewing, ensuring perfect alignment across seams.

Post-Construction Printing

Garments can also be printed after assembly using screen printing, DTG, or DTF methods.

Embroidery Integration

Embroidery can be incorporated during or after construction for added durability and detail.

Common Uses of Cut-and-Sew in Australia

Cut-and-sew is widely used for:

• Fashion and streetwear brands
• Sports and teamwear uniforms
• Corporate and promotional apparel
• Merchandise and private label collections

These applications benefit from custom sizing, fabric selection, and premium finishes.

Practical Considerations for Cut-and-Sew Projects

Minimum Order Quantities

Cut-and-sew production typically requires higher minimums compared to blank garment printing.

Lead Times

Production timelines are longer due to pattern making, cutting, and assembly stages.

Cost Structure

Cut-and-sew garments have higher upfront costs but deliver greater design flexibility and exclusivity.

Cut-and-Sew vs Printing on Blanks

Printing on blank garments offers faster turnaround and lower costs, while cut-and-sew provides unmatched customisation and brand differentiation. The right approach depends on project goals and budget.

Why Cut-and-Sew Matters in Custom Apparel

Cut-and-sew represents the highest level of garment customisation. For Australian custom apparel printing, it enables brands to create unique, purpose-built garments that stand out through fit, construction, and design quality—supporting long-term brand identity and premium positioning