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Product Update 3: Construction

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Posted by Jenna A on 24 October 2013 at 11:00 AM

Time for update #3 on the production process. So far we've talked about how the fabric is made and how the pattern pieces are cut – now it’s time to dive into the garment construction!

So, where can we start to share an overview of the mammoth task of garment construction?

1.  Planning the process – Before the pattern pieces reach the construction stage, the sample (prototype) technician has planned out the exact process through which each and every garment will be constructed. Each machinist will be allocated a different set of tasks per garment style in order to create the most efficient process for production. 

2. Applying the heat transfers - All of the heat transfer branding on our products is designed to work with high stretch sports performance fabrics, offering great stretch and recovery and a soft hand-feel. We opted for heat transfer for all branding elements to achieve an anti-chafe, performance finish on your products. These precision cut branding features are applied to the fabric before the pattern pieces are sewn together to ensure the exact placement of the heat transfer branding is correct.

Heat Transfer

The heat transfer detail is carefully laser-positioned matching the exact dimensions that we provide in the product design pack. The branding is applied and heated at 140~150°C for ~15 seconds under 3.5kg of pressure. The time, temperature and pressure for the transfer instruction varies for different fabric and transfer composition.

(Note this is a smaller machine from the sample room, just displayed for example purposes)

3.  Construction - the production line will follow EXACTLY the samples technician’s construction plan to manufacture the garments. Take the Women’s 2-in-1 Performance Shorts for example... One technicians job may be be to focus on removing the raw edge of the fabric from the pattern pieces before it moves to the flatlock machine for the seams to be constructed, to ensure a clean finish.

Shorts Trim

Another will focus on elasticating the extended waistband.

Elasticated Waistband

Whilst another creates the inner hidden key pocket and another group works on constructing the woven outer shorts...

Shorts Construction

And that's just a few stages on one of the products, there are hundreds of different construction processes across the entire range which go towards creating Tribesports Performance wear.

Zip construction for custom zip compartments in a garment add complexity to the construction process. The pattern piece that creates the outer zip pocket requires an incision where the zip is to be added. Then a stencil is created and used to apply a chalk outline on the outside face to direct the machinist the sewlines that must be followed when adding the zip to the pattern piece. The tiny zip garages are then added at either end of the zip, to ensure the your lockdown zip puller is fully secured down. A performance enhancing feature and one less thing to think about when you are working out!  

Zip being sewn in

The construction process is very detailed and comprehensive process that varies considerably from product to product. The machines used also vary from product to product, depending whether the machinist needs to construct a twin needle hem, and overlocked collar, a flatlocked seam etc.

One of the many reasons that we chose to work with the factories that we have to produce the Tribesports Performance wear is because they specialise in creating performance apparel for the leading brands around the globe and invest significantly in cutting edge machinery to ensure the highest level of construction quality, specific to the needs of performance sportswear customers.

4.  Quality control - Once the garment is assembled, the quality control team goes through each individual garment seam by seam checking that all mesaurements are correct and ensuring the highest construction quality.

Quality Control

Wondering what the orange and clear wires are in the photos from the quality control room? These omit compressed air to allow the technicians to clear the fibres from their desks as they work.

Next step - the finishing touches and packaging! 

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