Quick answer: Soccer jerseys are made by designing the artwork, sublimating it onto polyester fabric, cutting and sewing the panels, adding crests, names and numbers, then inspecting and packing.
A modern soccer jersey looks simple, but it passes through more than ten production stages before it reaches a player or a store shelf. Knowing how soccer jerseys are made helps brands and clubs write better briefs, approve samples with confidence and avoid the faults that cause returns. This guide walks through the full soccer jersey manufacturing process as it happens on our factory floor in Sialkot, Pakistan.
Quick answer
Soccer jerseys are made by designing the artwork and pattern, printing the design in mirror image onto transfer paper, sublimating it into white polyester fabric under heat and pressure (around 190–205°C), cutting the printed panels, stitching them with overlock and flatlock seams, adding badges, names and numbers, then inspecting, pressing and packing. A sample takes about 7–10 days; a bulk order of jerseys typically takes 2–4 weeks after sample approval.
Made under one roof in Sialkot. Ravix Pro Industry is a sportswear manufacturer, serving sports clubs and clothing brands worldwide: design, sublimation, cutting, stitching, embroidery and quality control all happen in-house, so colours, fit and delivery dates stay under control. MOQ 30 pieces per design. Soccer jersey manufacturing for brands · Get a free quote.
Part of our guide: Clothing Manufacturing Lead Times: Sample to Delivery · Quick answers
The soccer jersey manufacturing process at a glance
| Stage | What happens | Typical time |
|---|---|---|
| 1. Design and tech pack | Artwork, colours, logos, fit and size chart agreed | 1–3 days |
| 2. Pattern and grading | Panels drafted and graded across youth and adult sizes | 1–2 days |
| 3. Fabric selection | Polyester interlock, mesh or jacquard chosen and tested | In parallel |
| 4. Print file and RIP | Artwork laid onto each panel, mirrored, colour-managed | 1 day |
| 5. Printing on paper | Sublimation ink printed onto transfer paper | Hours |
| 6. Heat transfer | Calender or heat press transfers ink into the fabric | Hours |
| 7. Cutting | Printed panels cut by hand, die or laser | Hours to 1 day |
| 8. Stitching | Panels joined, neck and hems finished | Several days in bulk |
| 9. Badges, names, numbers | Embroidered or heat-applied crests and trims | 1–2 days |
| 10. Quality control | Measurements, print, seams, AQL inspection | Ongoing and final |
| 11. Pressing and packing | Thread trimming, folding, labels, polybags, cartons | 1–2 days |
Step 1: design, tech pack and size chart
Everything begins with a clear brief: front and back artwork, Pantone references, crest and sponsor files in vector format, neck style, sleeve type and a size chart. Brands usually send a tech pack, while clubs often send a sketch or a reference shirt. We return a digital mock-up for approval. Our tech pack guide explains what to include.
Step 2: pattern making and grading
The pattern maker drafts each panel (front, back, sleeves, collar, side panels) and grades it into every size. For sublimated jerseys the artwork is placed on the pattern panels themselves, so stripes and graphics line up across seams once the shirt is sewn.
Step 3: choosing the fabric
Sublimation only bonds properly with polyester, so performance jerseys are made from 100% polyester or high-polyester blends. Common choices are smooth interlock for sharp graphics, micro mesh for breathability and jacquard for built-in texture, at roughly 120–170 GSM. See what is GSM in fabric.
Steps 4–6: sublimation printing
The approved artwork is colour-managed in RIP software and printed in mirror image onto sublimation paper. The paper and white fabric then pass through a heated calender or flat press, usually at around 190–205°C for under a minute. The heat turns the ink into a gas that enters the polyester fibres and becomes part of them, which is why sublimated jerseys never crack or peel. Colour is checked against the approved sample under daylight conditions. More detail in sublimation vs screen printing.
Step 7: cutting the printed panels
Printed fabric is cut along the panel outlines. Small runs are cut by hand with straight knives; repeat styles may use dies or laser cutting, which also seals polyester edges. Accurate cutting matters because a few millimetres of drift will misalign stripes at the side seams.
Step 8: stitching and construction
| Seam / machine | Where it is used | Why |
|---|---|---|
| Overlock (serger) | Side and shoulder seams | Strong, stretchy seam that finishes edges |
| Flatlock | Panels and sleeves on performance jerseys | Flat seam that reduces chafing |
| Coverstitch | Hems and neck binding | Neat, elastic hem finish |
| Single needle | Collars, labels, details | Precision for small parts |
Step 9: badges, names and numbers
With full sublimation, names, numbers and sponsors are printed in step 5. Clubs and brands often add a premium crest: embroidered, woven, silicone, TPU or high-definition heat-applied badges. These are pressed or stitched on after sewing and checked for position with a template.
Step 10: quality control
- Measurement checks against the size chart and tolerances
- Print checks for colour, alignment, white creases or ghosting
- Seam strength, skipped stitches and loose threads
- Name, number and size checks against the roster
- Final AQL inspection before packing
Our sportswear quality control guide explains AQL levels and common defects.
Step 11: pressing, packing and shipping
Jerseys are thread-trimmed, lightly pressed, folded, labelled and packed individually or by player. Brands can add hang tags, barcodes and branded polybags. Cartons are packed by size or roster and shipped by air or sea with export documents.
From our factory floor in Sialkot
Ravix Pro Industry has made sportswear in Sialkot since 2008, following the same 11 steps on every order: quote, design, approval, sample, cutting, decoration, stitching, thread trimming, quality check, packing and door-to-door shipping. The two faults we work hardest to prevent are colour shift between batches and stripes that do not meet at the side seams. We control the first by printing reorders from the saved, colour-managed file of the approved sample, and the second by marking seam lines into the print file itself. See our manufacturing process and quality assurance.
Want to see your design made? Request a free quote or message us on WhatsApp with your artwork and quantities. MOQ from 30 pieces per design, samples in about 7–10 days. Explore soccer uniforms.
FAQs
What material are soccer jerseys made of?
Most are 100% polyester interlock, mesh or jacquard knit, typically 120–170 GSM, because polyester wicks sweat, dries fast and accepts sublimation printing.
How long does it take to make a soccer jersey order?
About 7–10 days for a sample and 2–4 weeks for bulk production after approval, plus shipping time.
Why do sublimated jerseys not crack or peel?
The ink turns into a gas under heat and bonds inside the polyester fibres, so there is no layer on top of the fabric to crack.
Can cotton jerseys be sublimated?
No. Sublimation needs polyester. Cotton or cotton-rich retro shirts use screen printing, embroidery or DTF instead.
What is the minimum order to manufacture soccer jerseys?
At Ravix Pro Industry the MOQ is 30 pieces per design, with mixed sizes, names and numbers.
Related guides: soccer jersey manufacturer for brands, custom soccer jerseys and football kits, how sportswear is made, sportswear manufacturing process.
Sources
- Ravix Pro Industry production records and process standards, 2008–2026.
- APP: Pakistan sports goods exports FY2025-26 (PBS data)
