Custom Underwear Manufacturer
Custom Underwear Manufacturer — Private Label & Cut and Sew Production
At DesignTo Clothing, we manufacture custom underwear built entirely from your specifications — fabric, fit, waistband, construction, and branding. Every piece is produced through our cut and sew production process from performance and comfort fabrics, not decorated blanks.
Underwear is one of the most fit-critical garment categories in apparel. The fabric needs to be soft against the skin, breathable, moisture-wicking, and durable through hundreds of wash cycles. The construction needs clean seaming, precise elastic tension, and consistent sizing across every unit. And the branding — especially the waistband — is where your brand identity lives. We manage all of it.
Our minimum order starts at 30 units per style and color — accessible for DTC underwear startups, lifestyle brands expanding into intimates, athleisure labels, and established companies scaling production.
Underwear Styles We Manufacture
Men's, women's, and unisex styles. Every piece is fully customizable — fabric, fit, waistband, and construction.
Boxer Briefs
Fitted through the thigh, 5–9 inch inseam. Combines brief support with boxer coverage. Standard, athletic, and long-leg options. The most popular men's underwear style.
Trunks
Shorter than boxer briefs, 3–5 inch inseam. Square-cut, streamlined silhouette. Popular with younger demographics and fashion-focused underwear brands.
Briefs
Classic coverage, no leg extension. Full coverage and bikini cuts. The traditional men's style and the standard for women's everyday underwear. A core product for basics brands.
Boxers
Loose-fitting, relaxed shorts-like cut. Woven or knit construction. Breathable for loungewear and sleepwear. Button fly, open fly, or no-fly options.
Bralettes
Wire-free, unstructured with soft support. Triangle, scoop, racerback, and longline designs. Light to medium support. A rapidly growing category for DTC intimates, athleisure, and loungewear.
Thongs & G-Strings
Minimal coverage with narrow rear panel. V-string, T-back, and seamless constructions. For everyday wear, fashion intimates, and matching bralette sets.
Boy Shorts
Full-coverage women's style with short leg extension. Comfortable, sporty, and casual. Popular for loungewear, sleepwear, and comfort-first brands. Available in fitted and relaxed cuts with a range of waistband options.
Fabrics and Materials
The fabric is the most important decision in underwear. It determines comfort, performance, and how the garment holds up through hundreds of wash cycles.
Modal & MicroModal
The premium standard. Made from beech tree pulp. Incredibly soft, lightweight, breathable, and shrink-resistant. Gets softer with each wash. The go-to for premium DTC underwear.
Holds color well · Luxury hand feel · Premium price point
Combed Cotton
The classic underwear fabric. Soft, breathable, affordable. Shorter fibers removed for smoother, stronger yarn. Ring-spun available for a finer hand feel.
Most common for basics and value-tier underwear
Bamboo
Naturally antibacterial, moisture-wicking, temperature-regulating. Softer than cotton with a silky hand feel. Eco-friendly fiber blended with spandex for stretch.
For sustainability-focused brands · Sensitive skin friendly
Microfiber & Nylon
Smooth, lightweight, quick-drying. Excellent stretch and recovery with spandex. Primary fabric for performance and athletic underwear. Compatible with seamless construction.
Silky hand feel · Works for both men's and women's
Mesh
Open-knit for maximum airflow. Full-construction or panel inserts at high-heat zones. Athletic, performance, and fashion-forward underwear where ventilation and texture matter.
Popular as accent panels or full-body for statement pieces
Organic & Sustainable
Organic cotton, recycled nylon, recycled polyester, and Tencel (lyocell). For brands leading with environmental values and certified products.
GOTS · GRS · OEKO-TEX certifications available
Learn more on our fabric and material processing page.
Construction Details
Underwear construction is precision work. Every detail affects comfort, fit, support, and durability.
Waistband
Fly, Gusset & Seaming
Leg Openings
Printing and Decoration
Targeted decoration focused on waistband branding and subtle, skin-comfortable detailing.
The primary branding method for underwear. Your logo woven into or printed onto the elastic waistband. This is the single most important branding element — it's what customers see every time they put on or take off the garment. Fully custom colors, width, and repeat pattern.
Small logos on hip, thigh, or rear. Water-based inks for soft hand feel on intimate fabrics. Keep prints minimal for comfort against skin.
Full-color all-over prints with zero hand feel. Only on white/light polyester or microfiber. Bold patterns, artwork, and statement underwear.
Small logo on waistband exterior or hip. Premium textured detail. Used sparingly on intimate garments.
Small logos and tagless interior branding. Soft hand feel for maximum comfort. Cost-effective for simple branding.
Branding and Private Labeling
Every piece fully branded as your own through our private label services.
Jacquard woven or printed elastic with your logo. The defining element of an underwear brand. Custom width, color, repeat.
Woven or printed at center back waistband or side seam.
Inside waistband with your sizing (XS–3XL or custom).
Printed onto garment interior. No sewn label irritation — critical for underwear.
FTC-compliant for your fabric. Details here.
Custom cards for retail display, pricing, or barcodes.
Packaging for Underwear
Packaging depends on your sales channel — DTC e-commerce, retail, or wholesale.
Multi-Pack Boxes
2-pack, 3-pack, 5-packPoly Bags
Logo + barcode wholesaleBranded Pouches
Premium DTC + giftingHeader Cards
Peg display for retailBelly Bands
Wraps for multi-packsPackaging produced alongside your order. Full options on our apparel packaging page.
Our Underwear Manufacturing Process
Every order follows a structured workflow from concept to finished product.
Design & Specifications
Send your design — sketches, reference photos, tech pack, or description. We confirm style, fit, fabric, waistband type, fly option, gusset, seaming, and branding details.
Fabric & Elastic Sourcing
Fabrics and branded elastic sourced to your specs — fiber, weight, stretch, hand feel, and certifications. Swatches and elastic samples for approval. Learn more.
Cutting & Sewing
Patterns cut and assembled through cut and sew production. Waistband, gusset, leg openings installed. Elastic tension calibrated for consistent fit across all sizes.
Decoration
Waistband branding, screen printing, sublimation, embroidery, or heat-transfer labeling applied per your specifications.
QC & Packaging
Every piece inspected for construction, elastic tension, waistband alignment, sizing consistency, and fabric quality. Labeled, tagged, packed into multi-packs or individual bags, and shipped. Quality standards.
Why Brands Choose DesignTo Clothing for Underwear Manufacturing
Complete underwear production — from fabric and elastic sourcing through construction, branding, and packaging under one pipeline.