Cycling Jersey Manufacturer for Teams and Brands That Reorder
Jafsu Enterprises is a cycling jersey manufacturer cutting, sublimating and sewing race jerseys, bib shorts and full kits to your own pattern and written spec. Samples start at one piece, production at 20 and bulk price breaks at 100 — with dyeing, stitching, chamois insertion and packing all done in our own building in Sialkot, which is what keeps season two matching season one.
WhatsApp +92 347 0849427 · info@jafsuenterprises.com · every enquiry answered within 24 hours
What Does a Cycling Jersey Manufacturer Actually Do?
A cycling jersey manufacturer prints your artwork into the fabric by dye sublimation, cuts the dyed panels to your block and sews them into a finished jersey with your zip, gripper, pockets and neck label. Jafsu Enterprises does that from a one-piece sample and a 20-piece low MOQ in Sialkot, Pakistan, shipping to the UK, USA, Canada, the EU and Australia.
A wholesale cycling apparel manufacturer sells stock jerseys by the carton with your logo heat-pressed on top. A sublimated cycling jersey factory starts one step earlier: white fabric, your panel artwork, your pattern. That is the difference between a branded blank and custom cut and sew, and why edge-to-edge graphics and sponsor blocks crossing a seam are only possible on the second route.
A custom cycling jersey manufacturer should run both OEM and ODM on one line: bring a finished tech pack and we build to it, or bring a colourway and a deadline and our pattern room develops the block, panel layout and trims with you.
The harder question is not who makes your first 20 jerseys, but who makes the next 300 in the same shade. Teams change supplier after the reorder, when the club red drifts half a tone or a sleeve lands short on size L.
That happens when the spec lives in a chat thread instead of a written sheet carrying ink references, measurements and tolerances. The numbers below are what that sheet should hold.
Custom Cycling Kit, Built to Your Block
Six builds cover almost every kit that leaves the floor, each cut to your measurements and fabric weight — never a stock body with a badge on it.
Short-sleeve road jerseys
Race, club and relaxed cuts in micro-mesh polyester with laser-cut sleeve bands and three rear pockets. A full zip custom cycling jersey runs on a YKK camlock that holds open on a climb, and custom road bike jerseys ship from the 20-piece low MOQ.
Long-sleeve and thermal jerseys
Autumn and winter bodies in roubaix-style brushed fleece, with higher collars, longer tails and reflective piping. Artwork is re-laid for the longer sleeve panel so the graphic keeps its scale.
MTB and gravel jerseys
Looser trail bodies with raglan sleeves, drop tails and quarter zips. As a custom MTB jersey manufacturer we pattern these wider through the chest and shoulder — a road jersey graded up gives you a big race fit, not a trail fit.
Bib shorts and tights
Compression lycra bibs with multi-density chamois pads graded by ride length, silicone or raw-edge grippers and mesh braces. Bibs ordered with jerseys print on the same ink profile — two lots of one club colour read as a mismatch on the start line.
Skinsuits and aero kit
One-piece time-trial and road suits with bonded seams, textured sleeve fabric and a hidden rear zip. An aerodynamic cycling kit manufacturer earns the name at the pattern stage: fewer panels, seams routed out of the airflow, almost no ease.
Gilets, jackets and warmers
Windproof gilets, rain jackets, arm and leg warmers, socks and caps, printed from the jersey artwork file so the range still matches at the second order.
Six Lines That Decide Whether Your Reorder Matches
Send these to every cycling jersey manufacturer you shortlist. The ones worth working with answer in numbers; the rest answer with adjectives.
- Fabric weight in both units. 150 GSM and 4.4 oz/yd² are the same cloth; one conversion slip separates the summer mesh you costed from a jersey that rides hot.
- Knit and finish, not just “polyester”. Micro-mesh, interlock, lycra and brushed thermal all take sublimation ink differently, and a wicking or hydrophilic finish is what makes moisture-wicking cycling tops actually pull sweat off the skin.
- Ink and colour reference. A Pantone or physical swatch per colour. Sublimation dyes into the fibre, so a locked ink profile is the only thing that repeats a club shade on a reorder.
- Zip, gripper and pocket spec. Zip brand, length and type (camlock, reverse coil, hidden), gripper width, pocket depth and whether there is a fourth zipped valuables pocket.
- Chamois density and grade. Pads are specified by density and thickness against ride hours — a crit pad in a gran fondo kit is the commonest complaint on any custom cycling kit supplier’s desk.
- Measurement tolerance per point. Chest, body length and sleeve each need a stated allowance, or “close enough” is decided by whoever holds the tape.
A cycling jersey manufacturer quoting against this sheet instead of a photograph can cost it in 24–48 hours, and the sample you approve becomes the spec bulk is measured against.
The sheet travels with the order
Printing, heat pressing, cutting, stitching, chamois insertion and packing all happen in one building, so a bike apparel manufacturer bulk run never leaves the floor to a subcontractor. Measurements checked at inspection are the ones written at quoting, and your patterns and artwork stay yours.
Fabric Weights, Quantities and Lead Times
Every cycling jersey manufacturer should publish these in both units, because a factory quoting in GSM and a buyer costing in ounces are describing the same cloth. The conversion factor is 33.906.
| Garment | Fabric and construction | GSM | oz/yd² |
|---|---|---|---|
| Summer race jerseys | Micro-mesh and micro-perforated polyester | 110–140 | 3.2–4.1 |
| Club and MTB jerseys | Polyester interlock with mesh side panels | 140–180 | 4.1–5.3 |
| Long-sleeve thermals | Brushed roubaix or thermal knit | 200–260 | 5.9–7.7 |
| Bib shorts and tights | Nylon-elastane compression lycra | 220–280 | 6.5–8.3 |
| Gilets and shells | Ripstop, softshell or windproof laminate | 60–150 | 1.8–4.4 |
| Stage | What happens | Quantity / time |
|---|---|---|
| Mockup | Spec reviewed, artwork laid on the panel template, itemised costing returned | 24–48 hrs |
| Sample | One sewn jersey for fit, colour and hand-feel sign-off | 1 pc · 7–10 days |
| First kit run | One design, split across XS–3XL in your size curve | 20–40 pcs |
| Bulk 50–300 pcs | Production with inline and endline inspection | 14–18 working days |
| Bulk 500–1,000+ | Volume run; price breaks at 100 / 300 / 500 / 1,000+ | 20–25 working days |
| Dispatch | DHL, FedEx or UPS express, door to door | 4–6 business days |
| Payment | Samples 100% advance; bulk 50% deposit, balance before dispatch against QC photos and video | PayPal · Remitly · Western Union · wire |
Fit selector: how much ease should your jersey have?
Drag to compare the blocks we pattern from, the chest ease each carries and the rider each one is cut for.
How a Kit Order Runs Through the Factory
Every order takes the same five stages, whether it is 20 jerseys or 2,000.
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Enquiry and costing
Send a tech pack, a reference jersey or a sketch with measurements. Back comes a panel mockup and per-piece costing split by fabric, sublimation and trims.
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Pattern and spec lock
Block, size curve, GSM, colour references, chamois grade, zip and tolerances confirmed in writing. Revisions here cost nothing; the same one after printing costs a run.
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One-piece sample
One sewn jersey in your fabric, artwork and trims. Ride it, wash it, measure it. Nothing goes to bulk until you approve this piece.
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Production
Panel printing and heat pressing, cutting, flatlock stitching, chamois insertion, then woven labels and packing, with inline and endline checks.
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QC and dispatch
QC photographs and video reach you before the balance falls due, then express dispatch with tracking and paperwork handled here.
Four Kinds of Buyer, One Production Line
Cycling kit manufacturers see the same four buyers. The brief changes; the line does not.
Clubs and race teams
A 20-piece low MOQ means a club orders without collecting 200 pre-orders, then adds late joiners on a top-up run against the same locked spec.
Cycling apparel brands
OEM and ODM development for labels building a range: your block, your chamois grade, your neck label, artwork kept on file between drops.
Wholesale and bulk buyers
Distributors and retailers ordering repeat bulk volume from a wholesale cycling apparel manufacturer, with price breaks at 100, 300, 500 and 1,000+ pieces.
Events, studios and charities
Sportives, spin studios and charity rides, often alongside our fitnesswear production, so one order covers jerseys and indoor kit.
Cycling Jersey Manufacturer FAQ
What is the minimum order for custom cycling jerseys?
Samples start at one piece and bulk at 20 pieces per design, split across your size curve from XS to 3XL. Most cycling jersey manufacturers ask for 50 to 200, so a low MOQ of 20 lets a club or a young brand release a real kit without funding stock it has not yet sold.
What is the difference between OEM and ODM cycling kit?
OEM means you supply the design and tech pack and we manufacture to it exactly. ODM means we develop the block, panel layout, fabric and trim list with you from a brief. Both run on the same line, and both leave the artwork and patterns in your ownership.
Are custom sublimated cycling jerseys better than printed ones?
For cycling, yes. Sublimation bonds the dye inside the polyester fibre, so nothing sits on the surface to crack, peel or block airflow, and colour can run edge to edge and across seams — which a heat-pressed transfer cannot do cleanly.
Do you supply brands and clubs in the USA?
Yes. We manufacture in Sialkot, Pakistan and ship door to door to the USA, UK, Canada, Europe and Australia by DHL, FedEx and UPS, usually 4 to 6 business days. Ordering bulk from an overseas bike apparel manufacturer trades transit time against unit cost, and our quotes stay landed-cost comparable at volume.
What GSM should a summer cycling jersey be?
Most race jerseys sit between 110 and 140 GSM, or 3.2 to 4.1 oz/yd². Lighter micro-mesh moves air fastest but shows more through the fabric; 140 to 180 GSM interlock suits club and MTB bodies, where durability and print depth matter more than grams.
Can you match our team colours across a reorder?
Yes, when the colour is locked to a Pantone reference or an approved swatch at spec stage rather than a screenshot. We keep the ink profile and panel files on record, so a repeat run prints from the same numbers instead of a fresh colour match.
How much does a custom cycling kit cost in bulk?
Cost falls through more units per design, fewer colourways and a locked spec — not thinner fabric. Bulk price breaks apply at 100, 300, 500 and 1,000+ pieces, and a custom cycling kit supplier worth using itemises the quote by fabric, sublimation and trims so you can see which line to adjust.
Do you supply wholesale volumes and repeat orders?
Yes. Repeat runs are produced against the same written spec, with lead times of 14 to 18 working days for 50 to 300 pieces and 20 to 25 for 500 to 1,000+. Payment is a 50% deposit, balance before dispatch against QC photos and video.
Send the Spec. Get One Jersey Back.
Itemised costing and a mockup within 24–48 hours, a sewn sample in 7–10 working days, production from 20 pieces and bulk breaks from 100 — from a cycling jersey manufacturer that answers every enquiry inside a day.
WhatsApp +92 347 0849427 · info@jafsuenterprises.com · Instagram @jafsusports · every enquiry answered within 24 hours