Creating a high-quality custom sports jacket requires thoughtful attention to both functional construction and design aesthetics. Below is a comprehensive guide to key materials, techniques, and considerations that will elevate your custom jackets for sportswear brands.
1.Fabric & Bonded Construction for Jackets
1.1 Common fabrics :Nylon,Polyester,Softshell,Ripstop.
While nylon and polyester are widely used and well-known, let’s dive deeper into Softshell and Ripstop fabrics:
- Softshell
A flexible, comfortable, and functional composite fabric designed for sports and light outdoor activities. It strikes a balance between comfort, wind resistance, moderate water repellency, and breathability.
–Structure has below three types:
Outer Layer: Durable polyester or nylon with a DWR (Durable Water Repellent) finish
Middle Layer: TPU membrane for windproof, waterproof, and breathable performance
Inner Layer: Brushed fleece, microfleece, or soft touch backing for insulation
–Ideal For:
Spring/autumn sports jackets
Running, hiking, cycling
Urban athleisure and commuter jackets
Ripstop Fabric
A woven, tear-resistant fabric featuring a reinforced grid pattern. Thicker yarns are woven at regular intervals to create box-like structures that prevent tears from spreading
–Materials:
Nylon Ripstop, Polyester Ripstop, or blended versions
–Ideal For:
Outdoor sportswear
Rain jackets, windbreakers
Tactical and military gear
1.2 Bonded/Laminated Structures
Layer / 3-layer laminations:Face fabric + TPU/PU membrane + tricot or dot glue backing enhanced for waterproofing, breathability, and wind resistance
Key Considerations:
DWR treatment for water repellency
Fabric weight suitable for seasonal use (lightweight for summer, insulated for fall/winter)
2. Stitching & Seaming Techniques for Jackets
- Common Construction Types:
1) Flatlock stitching2) Overlock / Four-thread seams
3)Bound seams
4)Laser cutting for clean, precise finishes
5)Taped seams (Sealed seams): Prevent water penetration
6)Heat-sealed seams: Seamless, smooth finish with added wind resistance Key Tips:
Match stitching method to jacket use (e.g., sealed seams for waterproof styles)
Avoid seam placement in high-movement areas (e.g., underarms, shoulders)
3.Logo & Decoration Options for Sports Jackets
Techniques:
Screen printing / Heat transfer (TPU films)
Digital Direct-to-Garment (DTG)
Reflective printing (for nighttime visibility)
Embroidery / 3D embroidery (ideal for thicker fabrics)
High-frequency embossed logos / Silicone badges
Velcro patches for interchangeable branding
Key Considerations:
Avoid high-heat transfers on sensitive or laminated fabrics
Embroidery may impact waterproofness or hand feel on light fabrics
4.Structural Design Details for Jackets
- Essential Elements:
Zippers:Waterproof, two-way, or concealed zippers
Cuffs: Elastic, Velcro-adjustable, or inner storm cuffs
Hem: Adjustable drawcords, drop-tail designs
Hood: Removable, adjustable, or three-panel hood constructions
Pockets: Side, zipper, inner stash, or headphone-port pockets Tips:
Use cold-resistant, durable zippers to avoid breakage in winter
Reinforce seams around heavy-use pockets
Adjust hood size based on target demographics (e.g., Asian vs. Western fit)
5.Linings & Insulation for Jackets
- Common Linings:
1)Breathable mesh
2)Lightweight polyester taffeta
3)Self-fabric lining for premium appeal
4)Quilted insulation: Down, faux down, cotton fill, or Sorona® for eco options Tips:
Ensure quilting is properly stitched to prevent insulation shifting
Add ventilation zones or laser perforation for breathability in multilayer jackets
6. Reflectivity & Functional Features
- Optional Enhancements:
1) Reflective stripes or logos for night safety
2) Underarm or back vents for temperature regulation
3) Water-repellent visors and chin guards
4) Packable designs: Jackets that fold into pockets or hoods Tips:
Functional trims should maintain fabric balance and avoid adding excessive weight
Ensure reflective materials are durable and withstand repeated washing
Final Thoughts for Sports Jackets
A well-designed custom sports jacket is more than just appearance—it’s a blend of performance functionality, technical construction, and smart design details. Whether your brand focuses on urban athleisure or outdoor performance, choosing the right fabrics, construction, and embellishment methods will ensure both performance and visual appeal.
Looking for a trusted factory partner to bring your sports jacket designs to life?
Contact us to explore full customization options tailored to your brand’s identity and technical needs.
