Clarify the needs: key issues before customization
Before starting customization, the following core needs must be clarified first, so that subsequent design and production are more accurate:
Use scenarios: outdoor sports (need to take into account both warmth and breathability), daily warmth (focusing on comfort), medical use (such as arthritis patients need local thickening), etc. The scenario determines the priority of materials and functions.
Target population: adults/children, normal body type/special body type (such as fat/thin), gender differences (different male and female versions), etc., which affect the size range and tailoring design.
Functional requirements: whether it needs to be waterproof (outdoor scene), breathable (sweating during exercise), elasticity (close fitting without restraint), adjustable waist circumference (adapt to different body types), etc.
Budget and quantity: customized quantity (affects the unit price, usually MOQ ≥ 50-100 pieces), budget range (determines the material and process selection).
Material selection: insulation is the core, taking into account other performance
The core function of thermal shorts is "insulation", so the material must give priority to warmth, and at the same time supplement other performance (such as breathability, waterproofness, elasticity) according to the scenario.
1. Insulation layer material
Natural fiber:
Wool (Merino wool): natural insulation, moisture absorption and perspiration, antibacterial, suitable for daily warmth or light outdoor, but the cost is relatively high.
Down (duck down/goose down): high fluffiness, excellent thermal insulation (note that the down content ≥80%, fluffiness ≥600+), suitable for extremely cold environments, but easy to lose effectiveness when exposed to water (need to be matched with a waterproof outer layer).
Synthetic fiber:
Fleece (such as Polartec): light, quick-drying, stable thermal insulation (still warm when wet), suitable for outdoor sports, but slightly weaker in breathability than wool.
Synthetic cotton (such as Primaloft, 3M Thinsulate): imitation down structure, light, waterproof, thermal insulation close to down, suitable for humid environments (such as skiing, rainy outdoor).
Phase change material (PCM): adjusts temperature (absorbs/releases heat) through microcapsule technology, suitable for scenes requiring dynamic thermal insulation (such as body temperature changes during exercise), but the cost is relatively high.
2. Surface/Inner Layer Materials
Surface (outer layer): needs to be wear-resistant and tear-resistant. Outdoor scenes need to be waterproof (such as coating/membrane materials, such as DWR waterproof coating, TPU membrane) or windproof (such as high-density nylon).
Inner layer (skin-friendly layer): needs to be soft, skin-friendly, and moisture-wicking (such as cotton, bamboo fiber, modal). Antibacterial fabrics (such as silver ion coating) can be used for medical purposes.
3. Auxiliary materials
Elastic materials: spandex (such as Lycra) needs to be added to the waistband and trouser legs to ensure that they are close to the body without being tight; sports models can add elastic stitching on the side seams (such as mesh fabrics) to increase freedom of movement.
Seams/strips: Waterproof models need to use seamless bonding technology (such as hot-melt adhesive strips) or waterproof stitching to avoid water seepage.
Design points: structure determines comfort and functionality
The design of thermal shorts needs to balance "insulation" and "freedom of movement", focusing on the following details:
1. Version design
Close-fitting style: suitable for daily warmth or as an inner layer (such as ski liner pants), it needs to be cut according to ergonomics (such as widening at the hips and thighs) to avoid a sense of restraint.
Loose style: suitable for outer wear (such as outdoor sports outer pants), it is necessary to reserve space for movement (such as three-dimensional cutting at the knees) to facilitate bending.
Partial thickening: For medical purposes, the insulation layer can be thickened at key parts such as the knees and waist (such as double-layer fleece or down patches).
2. Functional details
Waist design: adjustable drawstring or elastic waist (adapt to different waist circumferences) to avoid tightening the waist; medical models can be designed with high waist (covering the abdomen).
Pants design: closed trouser legs (windproof) or straight trouser legs (easy to put on and take off), sports models can add silicone anti-slip strips (to prevent sliding up).
Pockets/decorations: Outdoor models can be designed with invisible pockets (to store small items), and daily models can add brand logos or reflective strips (to improve safety).
3. Size and fit
Provide standard size charts (such as S/M/L/XL) or customize special sizes (such as children's sizes, plus sizes), which need to be adjusted according to the body data of the target population (such as the difference in body shape between Asians and Europeans and Americans).
IV. Production process: key steps from proofing to delivery
The customized production of thermal shorts is usually divided into the following stages, and the cycle is generally 15-45 days (depending on the quantity and process complexity):
1. Demand confirmation and proofing
The customer provides the demand (scenario, quantity, budget, design drawings/reference samples), and the manufacturer provides material suggestions and preliminary plans.
Proofing (1-3 pieces): Confirm the version, size, color, and functional details (such as whether it is waterproof). After the sample is approved, it will enter mass production.
2. Material procurement and cutting
Purchase fabrics and accessories (such as zippers and buttons) according to the order quantity, and the fabrics need to be pre-shrunk (to avoid shrinkage of the finished product).
Computer typesetting and cutting (precisely control the size and reduce waste), key parts (such as insulation layer) need to be positioned and cut (to ensure uniform filling).
3. Sewing and processing
Sewing process: ordinary sewing (firm stitches) or seamless lamination (waterproof models are glued with hot melt adhesive strips to avoid pinhole water seepage).
Filling insulation layer (down/synthetic cotton): needs to be fixed by quilting (to prevent the filling from shifting), and the quilting spacing is uniform (affecting the insulation effect).
4. Quality inspection and packaging
Quality inspection: check the size, firmness of the stitches, uniformity of the insulation layer, and functional details (such as waterproof test).
Packaging: customized packaging according to needs (such as brand paper boxes, PE bags), and instructions or maintenance labels (such as "machine washable, low temperature drying") can be attached.
