QUALITY CONTROLLED
CUT & SEW MANUFACTURING

Custom clothing production in Downtown LA. From pattern to finished garment, we manage the entire manufacturing process. Low minimums, quality control, and Made in USA.

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FULL-SERVICE CUT & SEW PRODUCTION FOR EMERGING & ESTABLISHED BRANDS

FS100 produces custom-made clothing from the ground up — your designs, your specifications, your brand identity built into every garment. Unlike private label (where you start with existing blank styles), cut & sew manufacturing means creating original pieces tailored to your exact vision, fit, and construction requirements.

We coordinate the entire production process in Los Angeles: pattern development, sample making, fabric sourcing, cutting, sewing, quality control, finishing, and packaging. You work with one partner instead of managing relationships with multiple contractors, fabric suppliers, and finishing facilities.

Our cut & sew program serves brands at every stage — from designers launching their first 50-piece collection to established labels producing seasonal runs of 500-2,000 pieces. We specialize in small-batch production with manageable minimums, fast communication, and the ability to pivot quickly when fit or construction needs adjustment.

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THE FS100 CUT & SEW PRODUCTION PROCESS

1. PATTERN DEVELOPMENT & GRADING

Every garment starts with a pattern. If you have tech packs and patterns ready, we review them for production feasibility and make recommendations if needed. If you're starting from scratch, we connect you with pattern makers in our network who specialize in your garment category.

Pattern grading (scaling your pattern across multiple sizes) happens before production. We grade patterns in standard sizing (S-2XL) or custom size runs based on your target customer. Grading ensures consistent fit across your entire size range.

Pattern approval: We produce a fit sample in your base size so you can approve the pattern before grading and production. Fit adjustments at this stage are normal — most patterns require 1-2 rounds of tweaking to dial in the right fit.

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2. PRE-PRODUCTION SAMPLE & FABRIC APPROVAL

Once the pattern is finalized, we produce a pre-production sample (also called a "salesman sample" or "SMS") in your chosen fabric. This sample represents exactly what the bulk production will look like — same fabric, same construction, same finishing.

You review the sample and approve:

- Fabric weight, hand feel, and drape

- Garment fit and construction

- Stitching, seam type, and finishing details

- Trim placement (buttons, zippers, labels, etc.)

No bulk production starts until you approve the pre-production sample. This checkpoint prevents costly mistakes and ensures the final product matches your vision.

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3. FABRIC SOURCING & INSPECTION

FS100 sources fabric through our network of domestic and international suppliers. We can source:

KNIT FABRICS: Jersey, rib knit, French terry, fleece, interlock, ponte, modal, rayon blends, tri-blends, performance knits.

WOVEN FABRICS: Cotton poplin, twill, denim, chambray, linen, canvas, oxford cloth, nylon, polyester, technical outerwear fabrics.

SPECIALTY FABRICS: Swimwear fabrics (nylon-spandex blends), activewear performance knits (moisture-wicking, compression), stretch wovens, coated fabrics, waterproof/breathable membranes.

Fabric lead times: Domestic fabric (in-stock from LA-based suppliers) can be sourced in 1-2 weeks. Custom or imported fabrics take 4-8 weeks depending on quantity and mill location.

All fabric is inspected upon arrival for defects, color consistency, and weight before cutting begins. Faulty fabric gets rejected and replaced before it reaches the cutting table.

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4. CUTTING

Fabric is spread in layers on cutting tables and cut using industrial straight-knife cutters or die-cutting for high-volume runs. Precision cutting ensures that all pattern pieces are accurate and that fabric waste is minimized.

Fusing and interfacing (if required by the garment design) happens during the cutting stage. Collar bands, cuffs, plackets, and waistbands receive fusible interfacing to add structure and prevent stretching.

Cut pieces are bundled by size and colorway and sent to the sewing floor with a work order specifying construction details, stitch type, and quality checkpoints.

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5. SEWING & CONSTRUCTION

Our contractor network in Downtown LA specializes in different garment categories:

KNIT SPECIALISTS: T-shirts, hoodies, sweatshirts, activewear, loungewear. Equipped with coverstitch machines, flatlock machines, and overlock sergers for clean, stretchy seams.

WOVEN SPECIALISTS: Button-up shirts, jackets, pants, dresses, skirts. Expertise in collar construction, sleeve setting, French seams, bias binding, and tailored details.

OUTERWEAR SPECIALISTS: Puffer jackets, windbreakers, coats, vests. Handle quilting, insulation insertion, waterproof zippers, and technical construction.

Quality checkpoints during sewing:

- Seam strength and stitch consistency

- Proper seam allowances (no raw edges or puckering)

- Correct placement of trims (zippers, buttons, snaps)

- Alignment of prints, stripes, or patterns across seams

Garments that fail quality checks are pulled off the line, corrected, and re-inspected before moving to finishing.

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6. FINISHING, PRESSING & INSPECTION

Once sewing is complete, garments move to finishing:

TRIMMING: Loose threads are clipped, and any remaining fabric tags or markings are removed.

PRESSING: Garments are steamed and pressed to remove wrinkles and set seams. Collars, cuffs, hems, and plackets receive final shaping.

LABEL APPLICATION: Your custom woven labels, care labels, and size labels are sewn or heat-sealed into place.

FINAL INSPECTION: Each finished garment is inspected for construction defects, fabric flaws, stains, or finishing issues. Garments that don't meet spec are flagged for repair or rejection.

Inspection pass rate standards: We target 95%+ pass rate on first inspection. Defective garments are repaired if possible or replaced if the defect is unfixable.

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7. PACKAGING & DELIVERY

Finished garments are folded, bagged (poly bags or branded packaging), and prepared for shipment. We can handle:

INDIVIDUAL RETAIL PACKAGING: Each piece folded, bagged, tagged, and ready for direct-to-consumer shipment or retail display.

BULK PACKING: Garments packed flat in boxes by size and style, ready for warehouse storage or distribution.

CUSTOM PACKAGING: Branded tissue paper, stickers, hang tags, custom mailers, and gift packaging for premium presentation.

Finished goods are shipped to your warehouse, fulfillment center, or retail location. We also offer short-term inventory storage in Los Angeles if you need a staging location before distribution.

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MINIMUM ORDER QUANTITIES: WHAT TO EXPECT

Cut & sew minimums are higher than private label because production setup (pattern grading, cutting, contractor setup) requires a baseline quantity to be cost-effective. We can offer NO-to-LOW MOQ’s for select styles.

Our typical minimums:

SIMPLE GARMENTS (t-shirts, basic hoodies, tank tops, sweatpants): 50-100 pieces per style per color.

MODERATE COMPLEXITY (button-up shirts, dresses, joggers with details): 100-200 pieces per style per color.

COMPLEX GARMENTS (outerwear, tailored jackets, technical activewear, swimwear): 200-300 pieces per style per color.

Why minimums exist: Contractors need enough volume to justify the time spent setting up machines, training operators on your specific construction, and maintaining quality control. Smaller runs increase per-unit cost significantly because setup time is amortized across fewer pieces.

Can minimums be lowered? Sometimes. If you're producing multiple styles in the same fabric and colorway, or if you're a repeat client with ongoing production, we can negotiate lower minimums. First-time production with a new contractor typically requires higher minimums.

Starting small: If your budget or market validation doesn't support 100+ pieces, consider launching with private label first, validating demand, then graduating to cut & sew once you have proven sales.

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GARMENT CATEGORIES WE PRODUCE

KNITS — T-Shirts, Hoodies, Activewear

T-SHIRTS: Crew neck, v-neck, scoop neck, henley, raglan, boxy fits, cropped, oversized. Construction details include shoulder-to-shoulder tape, side seams (or tubular), hem types (straight, curved, raw edge, blind stitch).

HOODIES & SWEATSHIRTS: Pullover hoodies, zip-up hoodies, cropped hoodies, oversized hoodies, crewneck sweatshirts, quarter-zip pullovers. Construction includes flatlock or coverstitch seams, ribbed cuffs and waistbands, kangaroo pockets, metal or plastic zippers, drawcords with metal aglets.

ACTIVEWEAR: Performance tees, sports bras, leggings, bike shorts, yoga pants, athletic tanks. Requires specialized contractors with experience in moisture-wicking fabrics, four-way stretch, flatlock seaming, and compression fits.

LOUNGEWEAR: Joggers, sweatpants, lounge sets, pajama sets. Elastic waistbands, drawcords, pockets, cuffed or open hems.

DENIM - High quality denim fabrics, production, washes/treatments. All made in Downtown Los Angeles!

LEATHER GOODS - High quality leather hides and production. Garments and accessories such as wallets, hand bags, etc.

HAT & ACCESSORIES - Custom made hats and other accessories. Inquire to Learn More

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WOVENS — Shirts, Dresses, Outerwear

BUTTON-UP SHIRTS: Dress shirts, casual shirts, camp collar shirts, overshirts. Construction includes collar construction (point collar, camp collar, band collar), button plackets, sleeve plackets, chest pockets, back yokes, and tailored fits.

JACKETS & OUTERWEAR: Coach jackets, bomber jackets, windbreakers, denim jackets, puffer jackets, parkas. Requires expertise in lining construction, insulation insertion, zipper installation, snap closures, and weatherproof seam sealing.

PANTS & SHORTS: Chinos, cargo pants, trousers, denim jeans, athletic shorts, casual shorts. Includes waistband construction, fly zippers, belt loops, pocket construction (side seam pockets, welt pockets, cargo pockets), and hem finishing.

DRESSES & SKIRTS: Slip dresses, midi dresses, maxi dresses, A-line skirts, pleated skirts. Construction includes bodice fitting, dart placement, lining, zipper insertion, and hem finishes.

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SPECIALTY — Swimwear, Uniforms, Technical Garments

SWIMWEAR: Bikinis, one-pieces, boardshorts, rash guards. Requires contractors experienced in stretch fabrics, lining, elastic application, and chlorine-resistant thread.

UNIFORMS: Corporate polos, work shirts, aprons, chef coats, medical scrubs. Often require specific fabric performance (stain resistance, durability) and consistent sizing across large orders.

TECHNICAL & PERFORMANCE: Waterproof jackets, insulated outerwear, compression wear, cycling apparel. Requires advanced construction techniques like seam taping, bonded seams, ventilation panels, and reflective detailing.

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PRODUCTION TIMELINES: WHAT TO EXPECT

Pattern development: 1-3 weeks depending on garment complexity and whether you're starting from scratch or refining existing patterns.

Sampling (fit sample + pre-production sample): 2-4 weeks total, including time for you to review and request adjustments.

Fabric sourcing: 1-2 weeks for domestic in-stock fabric, 4-8 weeks for custom or imported fabric.

Production (cutting + sewing + finishing): 3-6 weeks depending on order size and garment complexity.

Total timeline from pattern approval to delivery: 6-12 weeks for most projects. Simple garments with in-stock domestic fabric can be as fast as 4-6 weeks. Complex garments with imported fabric can take 12-16 weeks.

Rush production: Available for an additional fee. We can prioritize your order and expedite production to 3-4 weeks if fabric is already in stock and contractors have capacity.

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FREQUENTLY ASKED QUESTIONS

Do I need a tech pack to start production?

Tech packs are highly recommended and make production smoother, but they're not required. If you have detailed sketches, reference garments, or clear descriptions, we can work from that. We'll create a production spec sheet based on your input. We offer tech pack building service to create the proper assets your company needs to reproduce and minimize mistakes.

Can you help with pattern corrections if my samples don't fit right?

Yes. Fit adjustments are part of the sampling process. If your first fit sample is too tight in the shoulders or too long in the sleeves, we send it back to the pattern maker for correction and produce a revised sample.

Do you handle pre-production samples before bulk orders?

Yes. Pre-production samples (SMS samples) are mandatory before bulk production starts. This ensures you're approving exactly what will be produced at scale.

What's included in your cut & sew rate?

Cut & sew pricing typically includes labor only — cutting, sewing, finishing, and basic quality control. Fabric, trims, labels, and packaging are billed separately unless you're providing those materials yourself.

Can you source fabric, or do I need to supply it?

We can source fabric through our supplier network, or you can provide your own fabric if you have a preferred mill or specialty material. If you're supplying fabric, we'll provide a yardage estimate based on your order size and pattern.

What happens if there are defects in the finished garments?

Defective garments are repaired if possible or replaced if the defect is structural. Our contracts with factories include defect allowances (typically 3-5% of the order). If defects exceed that threshold, the factory is responsible for replacements.

Can you produce garments that are "Made in USA"?

Yes. All of our cut & sew contractors are located in Downtown Los Angeles. As long as your fabric is sourced domestically or imported and cut/sewn in the USA, your garments qualify for "Made in USA" labeling under FTC guidelines.

Do you handle ongoing production for repeat orders?

Yes. Once your first production run is complete, patterns, specs, and contractor relationships are locked in for future reorders. Many clients run seasonal production (Spring, Fall) or monthly restocks using the same setup.

Can you manufacture garments I design but also help with fabric selection?

Absolutely. Many clients come to us with design sketches but need guidance on fabric selection. We'll recommend fabrics based on your design intent, budget, and garment category, and provide samples for approval.

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READY TO START PRODUCTION?

Whether you're launching your first collection or scaling an established line, FS100 manages the entire cut & sew process in Los Angeles. From pattern to finished garment, we handle the details so you can focus on building your brand.