Inside the BKS Sportswear Factory: From Custom Design to Finished Teamwear

For overseas buyers, choosing a custom sportswear manufacturer involves more than reviewing a digital mockup or comparing quotations.

Buyers also need to understand what happens after a design is approved. How is the printed fabric prepared? How are garment panels cut? Who assembles the products? What details are checked before an order is packed?

Established in 2014, BKS Sportswear is a factory-based manufacturer specialising in custom sportswear, teamwear, school uniforms and training apparel.

In this article, we take you inside the BKS Sportswear factory and show several practical stages involved in turning a custom teamwear idea into finished garments.

Custom Teamwear Production Is More Than Sewing

A custom sportswear order normally passes through several connected stages. Depending on the product and decoration method, the process may include:

• Confirming product and order requirements
• Preparing and approving the artwork
• Selecting suitable fabric
• Sublimation printing or other decoration
• Preparing and cutting garment panels
• Sewing and garment assembly
• Adding trims, labels and product details
• Finishing and thread checking
• Checking sizes, names, numbers and quantities
• Packing and preparing the order for delivery

Each stage can affect the appearance, fit and consistency of the finished teamwear. This is why clear communication and product confirmation are important before bulk production begins.

1. From Approved Artwork to Printed Fabric

For fully sublimated teamwear, artwork is prepared before the individual garment panels are assembled.

Team colours, patterns, logos, player names and numbers can be incorporated into the artwork. The printed material then moves through the sublimation transfer process, where the design is applied to the fabric.

This method is frequently used for custom sportswear because it can support:

• Multiple team colours
• All-over patterns and graphics
• Player names and numbers
• Large front and back designs
• Integrated team branding
• Different artwork across individual garment panels

Because the design becomes part of the fabric surface, it does not sit on the garment as a thick printed layer.

Artwork approval is therefore especially important. Team colours, logos, names, numbers and spelling should be checked carefully before printed panels move into the next production stage.

2. Preparing and Cutting the Garment Panels

After the fabric or printed material is prepared, it must be divided into the individual panels that form the garment.

Depending on the product, fabric and order requirements, this stage may involve manual cutting, machine-assisted preparation or a combination of both.

A basketball jersey, rugby shirt, netball dress, training tee or school jacket may contain several differently shaped pieces, including:

• Front and back body panels
• Sleeves
• Side panels
• Collars and neck trims
• Armhole trims
• Waistbands
• Pocket pieces
• Internal lining components

Accurate cutting helps the sewing team assemble the garment according to the approved pattern and size specifications.

For sublimated products, panel positioning also matters because artwork may need to remain correctly placed or align across the garment seams.

Digital Pattern and Cutting Preparation

Digital equipment can assist with pattern layout, panel positioning and preparation before the pieces move into sewing.

Technology supports consistency, but production still depends on people reviewing the material, handling the garment components and checking the physical results throughout the process.

3. Sewing and Garment Assembly

Once the panels are prepared, they move to the sewing and garment assembly stage.

This is where the separate pieces begin to become a finished jersey, pair of shorts, jacket, polo shirt or other teamwear product.

The sewing process may include:

• Joining the front and back body panels
• Attaching sleeves
• Constructing collars and necklines
• Finishing armholes
• Adding side panels
• Constructing waistbands and drawcords
• Adding pockets where required
• Finishing hems
• Attaching labels and trims

Different apparel products require different construction methods.

A lightweight sublimated jersey does not use exactly the same construction as a school jacket, training hoodie or track pant. Fabric stretch, garment shape and intended use all need to be considered during assembly.

This is one reason buyers should clearly explain how the garment will be used when discussing a new project.

4. Finishing and Order Organisation

Production does not end when the final seam is completed.

Finished garments still need to be organised and reviewed before packing. At this stage, the production team may check and arrange details such as:

• Loose threads and general finishing
• Size grouping
• Player names and numbers
• Product quantities
• Labels and trims
• Matching jerseys and shorts
• Order-specific packing requirements

Organisation is particularly important for personalised team orders.

One order may include multiple sizes, individual player numbers, different names and several product categories. A clear order list helps the production and checking teams confirm that the correct items remain together.

5. Quality Checking Before Packing

A digital design may look correct on a screen, but the physical product still needs to be reviewed after production.

Depending on the product and order, quality checking may include:

• Garment measurements
• Stitching and seam construction
• Printed artwork positioning
• Logo placement
• Player names and numbers
• Visible fabric or printing issues
• Labels and trims
• Product quantities
• General garment finishing
• Packing requirements

The relevant checking points vary according to the garment.

For example, a fully sublimated basketball uniform may require attention to number positioning and artwork alignment, while a jacket may require additional checks around its zipper, pockets, cuffs and applied branding.

Approved artwork, size information and clear order documentation provide an important reference during this stage.

Why Factory Transparency Matters to Overseas Buyers

International customers cannot always visit a supplier before placing an order.

Real production images allow buyers to see more of the people, equipment and processes involved in manufacturing their products.

They can also help buyers ask more practical questions before starting a project:

• Does the supplier understand the required product?
• Can the supplier support the preferred customization method?
• Can a sample be reviewed before bulk production?
• How are artwork, colours and sizes confirmed?
• What details are checked during production?
• How are player names and numbers organised?
• How are finished garments packed?
• Who communicates updates during the project?

The objective is not simply to find a factory with sewing machines.

It is to work with a supplier that can coordinate product information, materials, artwork, customization, production and delivery requirements as one complete project.

Custom Apparel Manufactured by BKS Sportswear

BKS Sportswear supports custom apparel projects for sports clubs, schools, teams, organisations and apparel businesses.

Our main product categories include:

• Basketball uniforms
• Rugby uniforms
• AFL teamwear
• Netball uniforms
• Cricket uniforms
• Soccer uniforms
• Touch football apparel
• Training tees and shorts
• Warm-up jackets and hoodies
• Tracksuits
• School uniforms
• Coordinated team apparel

Explore our custom sportswear range, custom training wear and school uniform options.

What Should Buyers Prepare Before Contacting a Factory?

You do not always need a completed technical design before contacting BKS.

However, providing clear initial information can make the discussion and quotation process more efficient. Useful information includes:

• The product you want to manufacture
• Your estimated quantity
• Men's, women's or youth requirements
• Your team, school or brand colours
• Logo files
• Player name and number requirements
• Design or product references
• Preferred fabric or performance requirements
• Destination country
• Expected delivery requirements

After reviewing this information, the next steps may include confirming the product style, preparing artwork, discussing fabric options or developing a sample.

Read our detailed guide explaining how custom teamwear orders move from design to delivery .

Frequently Asked Questions

Does BKS Sportswear manufacture fully sublimated teamwear?

Yes. BKS supports fully sublimated custom apparel for a range of sports and teamwear applications.

Can we request custom colours, logos, names and numbers?

Customization can include colours, patterns, logos, names, numbers and selected garment details, depending on the product and production method.

Can buyers request a sample before bulk production?

Sample support is available to help buyers review the fabric, fit, artwork, logo placement and construction before bulk production.

Does BKS manufacture products other than match uniforms?

Yes. BKS also supports training wear, warm-up apparel, hoodies, jackets, tracksuits, school uniforms and other coordinated team products.

What logo files should we provide?

Vector files such as AI, EPS, SVG or editable PDF are preferred. High-resolution artwork can also be reviewed when vector files are unavailable.

Start Your Custom Teamwear Project with BKS

Every successful custom apparel project begins with clear information.

Share your product type, estimated quantity, colours, logo files, size requirements and delivery destination with BKS Sportswear. Our team can review the requirements and help plan the next stage of design development, sampling and production.