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Creating a shirt seems simple—but the timeline can surprise you. If you’re managing production for a brand, missed deadlines can mean lost revenue and unhappy customers.
A full shirt manufacturing process1—from concept to delivery—can take anywhere from 2 to 12 weeks depending on design complexity, production method, and supplier efficiency.
When I started Modaknits, I realized timing wasn’t just about production speed—it was about aligning every part of the supply chain. Here’s how we’ve optimized it, and what timelines to expect at every step.
What Are the Key Stages in Shirt Manufacturing?
To understand shirt lead time, we need to break it down into stages. Each one plays a critical role.
The shirt manufacturing process includes: tech pack creation, fabric sourcing2, sample development, bulk production, and final delivery. Each step has its own timeline that adds to the total lead time.
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How long does it take to design and develop a tech pack?
Designing a tech pack typically takes 3 to 7 days for basic shirts, and up to 2 weeks for complex designs.
A good tech pack includes technical drawings, measurements, material specifications, and construction details. For a brand owner, rushing this step can lead to costly errors later. At Modaknits, we often provide templates and design consultations to cut this down to 2–3 days.
What is the average time for fabric sourcing and approvals?
Fabric sourcing and approvals usually take 1 to 2 weeks, depending on fabric availability and testing requirements.
We maintain relationships with multiple mills to speed this up. If the client wants organic cotton or custom-dyed fabric, we factor in lab dips and compliance testing, which can add 3–5 extra days.
| Fabric Type | Average Time to Approve |
|---|---|
| Stock Fabric | 2–3 days |
| Custom-Dyed Fabric | 5–7 days |
| Organic Fabric | 7–10 days |
How Much Time Does the Actual Shirt Production Take?
Production time depends on equipment, labor force, and order volume.
On average, shirt production takes 5 to 15 days once everything is approved, but automation and factory efficiency make a big difference.
How long does it take to cut, sew, and assemble a shirt?
Cutting and sewing take 3 to 10 working days depending on factory scale and shirt complexity.
A simple crewneck T-shirt may take just 3 days in a large facility like ours. More complex shirts with zippers, pockets, or mixed materials could stretch production to 10 days. Worker training and shift management also impact this timeline.
Does manual vs. automated sewing affect production speed?
Yes—automated sewing3 can reduce production time by up to 30%, especially for high-volume orders.
Automated cutting machines and programmable sewing lines are game changers. However, luxury or tailored garments still rely on skilled hands. We often blend both for flexibility—using machines for consistency and artisans for detail work.
| Sewing Type | Time per Shirt (Estimate) |
|---|---|
| Manual Sewing | 25–40 minutes |
| Automated Sewing | 15–25 minutes |
What External Factors Can Affect Shirt Production Time?
No matter how well you plan, outside variables can cause delays.
Order size, design complexity, fabric availability, and third-party testing can all impact shirt manufacturing time.
How do order quantity and complexity influence lead time?
Larger and more complex orders naturally take longer, with lead times increasing proportionally with order volume.
A 300-piece run of simple tees can finish in under 2 weeks. But a 3,000-piece run with embroidery or color blocking can take a month. Smart batching and line balancing help us maintain efficiency even at higher volumes.
Can delays in fabric supply or quality control slow production?
Absolutely—late fabric deliveries or failed inspections can delay production by days or even weeks.
At Modaknits, we’ve seen projects stall for 10+ days because a mill failed a shrinkage test. That’s why we pre-book fabric and conduct pre-production QC to catch issues early. Shipping disruptions or port congestion can also push delivery dates.
What’s the Timeline Difference Between Fast Fashion and Custom Production?
Different production models = different speed and quality expectations.
Fast fashion prioritizes speed and low cost, while custom production takes longer but allows for brand-specific quality and design control.
Do print-on-demand shirts get made faster than bulk manufacturing?
Yes—print-on-demand shirts are often produced in 24–72 hours, but lack the fabric and construction quality of bulk manufacturing.
This method suits microbrands and influencer merch. But it limits customization options and may not meet retail-grade durability. For brands that care about longevity and fabric feel, POD isn’t always the best choice.
How long do luxury or handmade shirts take compared to mass production?
Luxury shirts can take 3 to 6 weeks due to hand-stitching, special fabrics, and multiple fitting rounds.
These garments often require manual embroidery, organic certification, or hand-dyed textiles. They also involve multiple rounds of sample feedback. For example, one of our European clients spends 2 weeks just finalizing collar structure for their bespoke shirts.
| Production Type | Average Time |
|---|---|
| Fast Fashion (Bulk) | 7–15 days |
| Custom-Made | 15–30 days |
| Luxury Handmade | 30–45 days |
How to Speed Up the Shirt Manufacturing Process?
Brands can’t always afford to wait. Good planning and strategic partnerships help shorten timelines.
You can cut production time by working with local suppliers, adopting digital sampling, or choosing vertically integrated factories.
Can using local suppliers or digital prototyping reduce lead time?
Yes—local sourcing and digital prototyping can shave off 20–40% of development time.
By sourcing locally, you avoid shipping delays and customs clearance. Digital prototyping tools like CLO 3D let you visualize fit and design before sample-making. We’ve cut our sampling phase from 10 days to 3 days using these tools.
What are the benefits of working with vertically integrated factories?
Vertically integrated factories streamline the process by handling everything from design to packaging in one place.
We own every part of our supply chain—from fabric sourcing to production. That means fewer miscommunications, faster turnarounds, and lower costs. Brands don’t have to juggle five different vendors. It also means faster issue resolution—if a fabric flaw appears, we can replace it same-day.
Conclusion
Shirt manufacturing can be as fast as 2 weeks—or take 2 months—depending on choices you make. Understand each stage, choose your partners wisely, and always leave buffer time.
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Understanding the stages of shirt manufacturing can help you optimize your production timeline and improve efficiency. ↩
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Exploring the impact of fabric sourcing on production time can help you make informed decisions for your brand’s supply chain. ↩
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Learning about automated sewing can reveal how technology can enhance efficiency and reduce production time in your manufacturing process. ↩
