Fashion Atlas Group/From Sample Revisions to a 115-Piece Custom Jersey Order

From Sample Revisions to a 115-Piece Custom Jersey Order

Developing a custom jersey for a fixed event deadline required more than simply approving a design and sending it to production. The client wanted a distinctive jersey with multiple branded elements, contrasting details, and a specific visual style, while the production timeline left little room for delays. As the project progressed, several design decisions changed during sampling. The challenge was to refine the garment without losing momentum or pushing the final order off schedule.

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Progress information

Step 1 — Developing the First Samples

The project began with fabric sourcing and sample development. Two factories prepared versions of the jersey, allowing the team to compare different production approaches before moving forward.

Once the first samples were ready, the client began refining the design further. He considered replacing the gray sections with black and asked whether white stitching could be added where the fabrics joined to create a more cohesive look.

Because the garments were already close to completion, the team finished the samples first rather than restarting the process immediately. Photos and videos were then shared so the client could evaluate the actual result before deciding which changes were still necessary.

His response to the overall quality was very positive, but several visual details still needed adjustment.

Back view of custom jersey sample with contrasting seam details

Close-up of contrast piping detail on a black custom jersey

Close-up of black custom jersey with striped ribbed collar

Close-up of striped V-neck collar and size label on custom jersey

<h2>Step 2 — Refining the Branding and Second Sample</h2>

The next stage focused on the areas that became clear only after the client saw the physical sample. Several logos needed corrected artwork, while others had to be reduced slightly in size to create better balance across the jersey.

Instead of moving straight into bulk production, the team collected the revisions into one clear set of instructions and developed a second sample.

Updated artwork was provided to the factory, and the revised version incorporated the corrected branding and requested design changes. The new sample was then photographed and filmed so the client could review the fabric, construction, proportions, and logo placement before giving final approval.

Further production details were confirmed at the same time, including black trim, size identification, standard packaging, and the size range from XS to XL.

This second sampling round helped resolve the remaining details before the project moved into full production.

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Step 3 — Moving Into a 115-Piece Production Run

After reviewing the revised sample, the client approved the jersey and confirmed the final order.

The production run consisted of 115 pieces across five sizes:

25 XS
30 S
30 M
25 L
5 XL

Once the size chart was approved, the factory purchased the fabric and began cutting. Production then moved forward under a tight schedule, with the order intended for an upcoming client event.

When the batch was completed, the production team carried out a final inspection, checking both quality and sizing before the jerseys were prepared for shipment.

The project demonstrates why sampling is especially important when custom apparel includes multiple branding elements and evolving design details. By using a second sample, confirming the artwork, and reviewing the finished garments before shipment, the team was able to turn a changing concept into a completed 115-piece custom jersey order without skipping the key approval stages.

From Sample Revisions to a 115-Piece Custom Jersey Order

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