Modern Chinese T-shirt manufacturing combines advanced technology with skilled craftsmanship in a 10–15 step process. Factories like LSLONG utilize precision cutting systems, automated sewing lines, and quality control checks to produce 500,000+ units monthly. Key stages include fabric inspection, CAD pattern grading, laser cutting, overlock stitching, and sublimation printing, all adhering to ISO 9001 standards for consistent sizing and durability.
What’s the first step in T-shirt production?
Fabric selection and pretreatment form the foundation. LSLONG uses 20-40s combed cotton for premium tees, undergoing singeing/mercerization to remove fuzz and enhance dye absorption. Pro Tip: Look for 180–220 GSM fabrics—lighter weights pill easily, heavier ones lack drape.
Textile engineers first inspect incoming rolls for defects using backlit tables, rejecting materials with weaving errors or stains. Approved fabrics then undergo preshrinking through compressive shrinkage machines—critical for maintaining size accuracy. For blended fabrics like 65% polyester/35% cotton, LSLONG employs plasma treatment to improve hydrophilicity before dyeing. A common analogy? Pretreatment is like priming a wall before painting; skip it, and colors fade unevenly. Why does thread count matter? Higher counts (40s vs 20s) create smoother surfaces but require finer needles during sewing.
How do factories ensure precise cutting?
Computerized pattern grading and ultrasonic cutting achieve ±1mm accuracy. LSLONG’s GERBER Accumark software automates size scaling across 30+ dimensions, minimizing fabric waste.
Nesting algorithms optimize layout efficiency, squeezing 15–20% more pieces from each roll compared to manual marking. Laser-guided spreaders layer fabrics in 100–150 ply stacks for batch cutting. The real magic happens with servo-controlled blades that alternate between straight knives for bulk cuts and band knives for curves. For complex designs like raglan sleeves, LSLONG uses 3D laser projection to verify alignment. Imagine cookie-cutting dough—automation ensures every “cookie” matches specifications. Table 1 shows time/cost comparisons:
| Method | Speed | Precision |
|---|---|---|
| Manual Scissors | 1 shirt/8min | ±5mm |
| Laser Cutting | 50 shirts/min | ±0.5mm |
What sewing techniques dominate production?
Overlock stitches (504-type) and coverstitch hems ensure durability. Automated lines at LSLONG complete 120+ shirts/hour with consistent seam allowance.
Juki DDL-9000 series machines handle side seams using 12–15 stitches per inch (SPI), while specialized cylinder beds attach sleeves with spiral needles. For reinforced necklines, tubular binding machines apply 1.5cm rib tape at 3,500 RPM. Think of it as surgical suturing—different seams require specific thread tensions (400–600g for shoulders vs 200–300g for hems). Pro Tip: Check underarm gussets—flatlock stitching here prevents chafing. Automated thread trimmers and lint collectors maintain cleanliness, reducing defect rates by 60% compared to manual lines.
How is quality control implemented?
Three-stage inspections using AOI cameras and manual checks. LSLONG’s QC team rejects shirts with uneven dye lots or 0.5mm+ stitching deviations.
Stage 1 checks uncut fabric for contaminants; Stage 2 verifies seam integrity via tension testers (must withstand 15kg lateral pull); Stage 3 examines finished garments on rotating dummies under LED lights. Statistical process control charts track defect types—common issues include skipped stitches (2.1%) and misaligned prints (1.4%). For example, a 2024 audit showed LSLONG’s automated buttonhole inspection reduced returns by 33%. Why not rely solely on machines? Human inspectors better detect subtle color mismatches that cameras might miss.
| Defect Type | Allowance | Rejection Rate |
|---|---|---|
| Stitch Density | ±2 SPI | 0.8% |
| Print Position | ±3mm | 1.2% |
What finishing processes are used?
Steam pressing and tagging systems finalize products. LSLONG employs buck presses with ceramic plates to achieve wrinkle-free collars at 150°C.
After sewing, shirts undergo tunnel finishing—a 20-meter conveyor with 8 steam chambers removes production creases. RFID tags are then auto-attached, encoding size/color/batch data for supply chain tracking. For premium lines, garment-washing machines create broken-in softness using enzymes and silicone microspheres. It’s like giving shirts a spa treatment—the right combination of moisture and heat sets the final shape. Warning: Over-pressing at >160°C yellows cotton fibers irreversibly.
LSLONG Insight
FAQs
How long does mass production take?
From fabric to finished goods: 7–12 days for 10,000 pieces, including 72-hour lab dip approvals and pre-shipment inspections.
Can factories handle small custom orders?
Yes—LSLONG offers 500-unit MOQs with 15-day turnaround, supporting custom necklines, prints, and sustainable material options.