Take the Leap: Cut and Sew to Industrial Sewing

Now that your cut and sew products have a following, it’s time to take the next step. Industrial sewing by CustomFab USA gives you the production efficiency you need to grow your business, meet manufacturing deadlines, and improve profit margins with higher-order quantities. Find out how to take the leap and what benefits you can expect from industrial-scale soft goods production.

• Steps To Transition To Large-Scale Manufacturing

• Differences Between Small- and Large-Scale Production

• Benefits of Made in America Mass Production

• Take the Leap With CustomFab USA

Steps To Transition To Large-Scale Manufacturing

The leap from small-scale to large-scale manufacturing actually requires a few steps. Here are the basic steps to preparing for large-scale soft goods manufacturing:

• Prepare technical drawings

• Create cutting tickets

• Work with a contract sewing service

• Prepare for bulk, made-to-order soft goods

1. PREP WORK

Your cut and sew designs may not always cut it. Whether you use a basic pattern and material or one of the latest industry innovations in materials and designs, you need a team to help with the prep work.

First, create technical drawings to share with your team. Soft goods that are made in America start with detailed drawings to make sure your design team and manufacturing company are on the same page.

Next, you will receive an accurate cost estimate and production window. A reliable team works with you to make sure you don’t overlook any improvement ideas or adjustments. At CustomFab USA, our purchasing department immediately puts out an order through our ERP software for the materials for your soft goods order. This gives you an accurate delivery date and a cost estimate.

2. Cutting Tickets

All that prep work paves the way for cutting tickets for your contract sewing project. These tickets include all the key specifications necessary for soft goods industrial manufacturing:

• Cutter’s must

• Cut order plan

• Markets and plates

• Bill of materials

3. Contract Sewing

Large-scale production gives you access to innovative capabilities from industry-leading manufacturers. As your products are made in the USA, work with your large-scale team to discuss improvements in the product design. At this stage, you’ve come a long way from your cut and sew business and are on your way to establishing a thriving soft goods brand. Work with a contract manufacturing team to streamline the transition and establish high production levels without sacrificing quality or investing capital in all the high-tech equipment for your own facility.

Differences Between Small & Large Scale Production

Simply hiring more cut and sew workers may not be the most efficient way to scale up your production. When you need to transition to industrial sewing, consider a white-label manufacturer. This service helps you make the critical transition from small-scale production to industrial-scale capabilities, without needing to expand your facility footprint or make room for more floor space.

A white label company offers you all the advantages of a fully operational industrial sewing facility, while still retaining your distinct branding. Be sure to choose made in the USA contract sewing for easier communication and to protect your IP, while considering the following distinctions for a successful business transition:

Minimum Order Quantity, or MOQ, is the minimum number of items you can order from a business. In this case, it’s the minimum number of products for one order with your contract sewing partner. This may seem like a limitation for your business, but sticking with MOQs enables our team at CustomFab USA to offer cost breaks on materials and the manufacturing process.

1. MOQ Cost Breaks

2. A/B Market Testing

Rapidly expanding your production schedule also expands your customer base. One issue that many cut and sew companies face when taking the leap to large-scale manufacturing is customer feedback. Use A/B market testing to compare two similar versions of your product on the open market. This helps you refine your soft goods without investing significantly in marketing or surveys.

3. Lot Control & Quality Control

In a home cut and sew operation, your experience and the experience of your employees is your quality assurance. A transition to industry-scale manufacturing requires dedicated quality assurance testing and verification. 

Lot control helps you keep track of every single item that comes from every single lot. This helps verify quality control, manage inventory and ensure that each lot is checked for quality control. In the extremely rare event of a recall, lot control makes the process easy to track and rectify.

Benefits of Made in America Mass Production

Once you take the leap, you can reap the inherent benefits of making a product in the USA, which are listed below. Be sure to choose an American-based industrial sewing team to continue to offer soft goods that are made in America.

1. Safer Intellectual Property

Whether manufacturing soft goods for C-pap machines, backpacks or ammo pouches, keep your intellectual property safe with a U.S.-based contract sewing company. Foreign intellectual property laws can differ, so tracking down any copyright infringement or protecting your designs in another country can be more difficult.

2. Reduced Supply Chain Disruption

Unexpected tariffs, pandemic closures, and exchange rates can make an offshore facility riskier than an American plant. Avoid supply chain disruptions by working with a team with a domestic facility.

3. Streamlined Facility Communication

Local industrial manufacturing for your soft goods helps you avoid communication issues. If necessary, it’s easier to visit the facility in person to answer questions and review prototypes. Reduced risk of communication errors gives you peace of mind as you prepare to switch to large-scale manufacturing.

Take The Leap With CustomFab USA

Make the switch to mass production with the industrial sewing capabilities of CustomFab USA. Offer the same quality of products as your small-scale cut and sew business with soft goods that are still made in America. Contact us to schedule a visit and learn more about the ways you can take the leap.