How To Make A T-Shirt From Design To Manufacturing Process

Hey hows it going guys John Santos and today I'm here at BELLA+CANVAS headquarters

which is one of the industry leaders of off the shelf blank apparel now what

they do is they actually control their entire operations so you're able to get

quality product and they actually allowed us to come in film and go over

their entire process of what it takes to create quality garments now in this

video we're going to cover the entire process meaning a design, pattern making,

grading, cutting, to sewing, fulfilment so you guys are really able to see the

entire gamut of the operation I hope you guys enjoy lets get it!

The design process starts

with a simple sketch one that you draw with the build of the shirt in mind

meaning you know exactly what angles the shirt might be when it's completed and

really keep the dimensions and unique features that you're working on as

you're drawing it now this is something that could be done on any simple paper

and once you get it done you're ready to start actually putting it together start

it off with your sketch here with the sketch that you created and obviously it

a the sketch did stay this way it evolved to become pattern this is gonna be that

perfect so we'll check that out to show you guys how this this thing went to

this for those of you guys that are watching this is a CAD based program

where all the patterns are created and actually developed and from here you

guys take these and you actually start grading on the sizes right and first we

want to establish the correct base size and fit and then we would grade from

there so remember we were talking about the sleeve shape being a European sleeve shape

so this is the entire front side of it, thats the front of the shirt

yes front panel and then over here is our cad and gives you like the goal with our

shirt should look some of our cads are

fantastically similar to the silhouette they just created the patterns over in

the computer and now they're going to print it onto this plotter and what this

plotter is it takes whatever was there and it creates the pattern for you to be

able to cut it out and actually cut out a sample of whatever you're working on

now we're going into the actual sampling side of things we're going to take them

to the cutting where you guys will see everything being cut and I'm got to be

kind of loud because it's loud in here but it'll be cool Summer there awesome

the man thank you for joining us a lot of fun the bella canvas

headquarters in LA houses the largest cutting facility in the USA this is

where they do their mass productions and process more than 2.5 million shirts per

week now that's a lot of shirts so you guys just saw us print the plotter now

were taking it to this area want to tell us a little bit about the fun and intricacies

of this exact process sure well it's not as fun unless you have a pair of

scissors this is Elmer, elmer is our sample cutter so we're about to cut this sample

from the pattern you just saw earlier all right elmer so we're take this pattern and

we're going to spread some fabric you have a heavyweight jersey available this

is our 5.5 heavyweight Jersey we do process dyes for our own colors so we

actually do control the whole supply chain so the dotted line is actually

called seam allowance and he's cutting on the cut line so when those pieces get

cut we're going to sew it inside out and sew the seam allowance goes away

because you'll have to use that seam allowance for your sewing operation and

we'll see that in a minute and he laid a piece of paper on the bottom of

the fabric yes there's two things one is stability also helps him

maneuver the fabrics and the cut piece on the table but it's also good for

labeling and other pieces like protects the fabric from getting dirty there's a

lot of purposes actually this is a castle notch the castle notch

allows you to know where to set the sleeve in a sewing process so that's why

not just exist for a location its for sowers but you have to be mindful of how you

spread fabric certan fabrics are delicate that requires a very delicate

skilled hand to cut now that we have the cut pieces we are ready to start sewing

up the first sample this sower knows exactly how everything is put together

so what you guys are going to see here is a very quick process and she didn't

have too much time to explain she takes the cut panels pieces them

together and now she goes on over to the shoulder tape the shoulder tape goes

across the shoulder and around the neck band it stabilizes the width so the

shoulders don't peak out and it also protects the back neck from the overlock

being exposed overall it helps shape the shirt and it's something that most

t-shirts do have so next time you guys wear one just check it out you'll be

surprised by the details that's in it

she then irons it for you so you're ready for a night out with the homies

now just kidding it helps keep the dimensions and it ensures that it

doesn't curl up while she is closing it up in sewing now the final piece of

the process is in closing up the shirt this is where the castle notch comes into

play it helps align the shirt to make sure that it's closing at the right


as you could see she was very experienced in the process obviously

when you go onto the production side of things everybody is set into a specific

position which from there creates that efficiency throughout the entire process

so you just saw what it takes to create a sample of a t-shirt now once the

sample is completed they're going to size it can make sure it fits according

to what they envisioned there's any changes they're going to make it and

after the changes are completed and the patterns are finalized it goes into

production so right now what we're going to do we're going to go in and talk to

the head of the production who's going to give us some information that you

guys could take forward and really know what goes into a quality garment alright

lets get to it these patterns then get checked from her they take these out to

the table and we do on the cutting what they call a dry run so basically that

they pass the information from in here they'll upload it to the computers on

the cutters and then she'll pull these markers out and then they'll just drop

paper on top and then the paper will cut the pattern and then they'll come and

check the hard pattern to the paper so one of the things that the tech is here

is doing is he's plotting a marker here and then basically what he's checking is

the consumption of the fabric so once he's put all the pieces in there he has to go

through and make sure that the number of pieces add up to the to the amount of

cuts that will be on there you don't want to leave out a sleeve or something

once he's assured that every all the numbers match and it will begin

plotting after the fabric is laid out this advanced machine which actually

costs a couple million dollars takes the information from inside of the computer

and pulls it into the system now this allows the cutter that's

operating the machine to simply pull up the cutting specs and from there you

just hit start and the Machine starts cutting it according to the details that

were inputted now this machine is really cool and one

of the key things that blew me away was the fact that I actually vacuum seals

everything before it's cut now what this essentially does is it allows every

single cut to be precise and prevents some shirts from being a different size

in another it cuts everything accordingly and it's

always the same cut as you guys could see they got a really very pro setup

when it comes to everything now once all the patterns are cut out

they are sewn up together during the sewing process for production each

worker is assigned a specific task and once it reaches the last person the

garment is fully completed now at this stage is where they actually do some

quality control make sure that everything was sewn up right there's

no loose threads or anything that's going to cause a return or a bad product

after it is sewn up and inspected it is ready to be shipped to customers around

the world now I want to show you guys how they operate the fulfillment side of

their business so you can visualize and see how you may be able to streamline

your operations at the bella canvas facility in LA they handle all sides of

the order from small online orders to large distribution once the orders come

in they assign the order to a staff member the member will pick the order

and they'll bring it to the packing area from the packing area that will double

check that the order is correct once it's approved it's ready to go somebody

wants to place an order online what's the soonest and the latest they can

place it and get it if they place the order online and we get it this ware

house by 4 o'clock it will be out the door that same day this is where receiving and this

is the conveyor system we're going to have pretty much up and running by next

month and again this will allow us to take a full container of about 1100 to

1200 cartons offloaded to sort it segregate and receive it in with less

than an hour and then as soon as that's in then we're putting it away and it's

going to put away it's available for sale so there you have it guys I hope

you guys enjoyed the entire process I wanted to cover the entire gamut for you

to better understand what it takes to create your own line from scratch now

look these are years of experience and know-how and millions of dollars

invested into this equipment you can also take a similar approach if you're

looking to start your own clothing line in a similar manner but for those of you

that don't want to spend a year's time energy to learn all of this you could

always find these items directly on their site the links are down below I

also highly suggest you subscribe to the YouTube channel you're able to see a

little bit more details as to their entire process in terms of printing and

how they get everything ready for you guys to order so also be on the lookout

for additional videos which are going to be releasing over the next few weeks but

we dive into a little bit more of those details and really interview a lot of

those people in detail to give you guys more content I just want to make sure

you guys got this video first so you get the entire overview and then we're going

to jump into those details so make sure you subscribe to this channel comment

down below if you guys have any questions more than anything

let's get it talk soon bye, wake up and win