Details Of Sewing and Assembly In Shirt Manufacturing Process

Sewing and Assembly are crucial stages in the shirt manufacturing process, where all the individual fabric pieces that were cut earlier are brought together to form the complete shirt. This step requires precision and skill to ensure that each part is properly aligned and stitched to create a well-fitting, durable, and aesthetically pleasing garment.Regal Rarities, this stage also includes incorporating unique design elements like hand embroidery, making the sewing process even more detailed.

Here’s a comprehensive look at the sewing and assembly process in shirt manufacturing, specifically for Cuban collar shirts made from linen.

1. Importance of Sewing & Assembly

The sewing and assembly process determines:

• Fit and Comfort: Precise stitching ensures that the shirt fits well and moves comfortably on the body.
• Durability: Strong and neat stitches prevent the shirt from coming apart over time.
• Visual Appeal: Well-executed seams and hems give the shirt a polished, high-quality finish, especially important for shirts featuring intricate details like embroidery.

Regal Rarities, maintaining both durability and aesthetic appeal is critical to delivering a high-end product that showcases Indian craftsmanship.

2. Steps in the Sewing and Assembly Process

a) Stitching the Body

1. Joining the Front and Back Panels:

   • The first step involves sewing together the front and back panels of the shirt at the shoulder seams. This is typically done using a lockstitch or overlock stitch to ensure the seam is durable and lies flat.
   • For your linen shirts, careful attention is given to ensure the shoulder seams align perfectly, as this is key to the shirt's overall fit and structure. The open, relaxed fit of the Cuban collar requires precision here to avoid any puckering or pulling.

2. Attaching the Sleeves:

   • The sleeves are then attached to the body of the shirt. Since you are producing half-sleeve Cuban collar shirts, the sleeve is attached along the armhole using a set-in sleeve method, which gives a clean, professional finish.
   • It’s crucial that the sleeve seams are reinforced to handle movement and wear. Linen, being prone to fraying, must be carefully hemmed or finished with an overlock stitch to prevent the edges from unraveling.

3. Sewing the Side Seams:

   • After the sleeves are attached, the side seams are sewn, joining the front and back panels from the underarm to the hem. For Cuban collar shirts, side seams are generally sewn with a French seam or a serged seam for a neat and durable finish.
   • A French seam is particularly useful for linen because it encloses the raw edges, preventing fraying and giving the interior of the shirt a clean, finished look. It also ensures longevity, even after repeated washes.

b) Constructing the Collar

1. Assembling the Cuban Collar:
   • The Cuban collar is one of the most distinctive features of your shirts, and it requires precision. The collar consists of a top collar and an under-collar that are sewn together and then turned inside out to create a smooth, crisp edge.
   • The collar is usually interfaced (a layer of fabric added to provide structure and stiffness) to ensure it keeps its shape. However, since Cuban collars are softer and more casual, a lightweight interfacing is used to maintain flexibility.
2. Attaching the Collar to the Body:
   • After assembling the collar, it is sewn to the neckline of the shirt. For Cuban collar shirts, this process is slightly different from standard collars because there is no collar stand. The collar lies flat against the body, giving it a more relaxed appearance.
   • Careful stitching is required to ensure that the collar is evenly aligned with the neckline, with no puckering or gaps. This is especially important for linen, as the fabric’s texture and drape need to complement the collar’s natural flow.

c) Adding Details (Pockets, Button Plackets, etc.)

1. Optional (Pocket Assembly):

   • If your Cuban collar shirt design includes a chest pocket, the pocket is sewn onto the front panel after the main body is assembled. The pocket edges are folded under and stitched in place, ensuring it is securely attached without visible raw edges.
   • For hand-embroidered pockets, extra care is taken to align the embroidery properly on the fabric before attaching the pocket to the shirt.

2. Button Placket:

   • The button placket is typically sewn onto the front of the shirt. It is a strip of fabric that holds the buttons and buttonholes, ensuring that the front panels stay closed when the shirt is worn.
   • For your linen shirts, extra attention must be given to aligning the placket correctly, especially if the shirt features any embroidery or pattern matching.

3. Hem Finishing:

   • The bottom hem of the shirt and the sleeve hems are finished using a double-fold hem or a narrow overlock stitch to create a clean, durable edge. Linen's tendency to fray makes it essential to use finishing techniques that enclose the raw edges.
   • The hem on a Cuban collar shirt is typically straight, giving it a casual, untucked style.

d) Buttonhole Making & Button Sewing

1. Buttonholes:

   • Buttonholes are made on one side of the button placket, using a buttonhole stitch. This is a dense, narrow stitch that reinforces the fabric around the hole, preventing it from fraying or tearing when the button is fastened.
   • On linen shirts, extra care is needed to prevent fraying, so the buttonholes may be reinforced with additional stitching or interfacing behind the placket.

2. Attaching the Buttons:

   • Buttons are sewn onto the opposite side of the placket. For Cuban collar shirts, four to six buttons are typically used, depending on the design. Buttons should be sewn securely, using a shank (a small loop of thread under the button) to allow the fabric to move easily without pulling the button too tight.
   • Since linen can stretch slightly over time, it's essential that the buttons are attached with enough thread to accommodate any natural give in the fabric.

e) Final Embroidery or Design Application

1. Hand Embroidery:
   • For Regal Rarities shirts, this stage would include adding any hand-embroidered designs that are part of the shirt’s aesthetic. Since embroidery is a central element in your brand, this process is done with great care, ensuring that the designs are centered, aligned, and finished to perfection.
   • Embroidery on linen requires careful handling to prevent puckering or distortion in the fabric. The fabric may be stretched slightly on an embroidery frame to keep it taut during stitching.

3. Final Quality Checks

After all sewing and assembly are complete, the shirt undergoes a final inspection to ensure quality and consistency. This stage involves checking:

• Stitch Quality: Ensuring that all seams are secure, neat, and free from loose threads.
• Embroidery: Verifying that the hand embroidery is intact and properly aligned with the design specifications.
• Fit: Ensuring that the shirt fits according to the size specifications.
• Button Functionality: Checking that all buttons are securely attached and the buttonholes are properly stitched.

Any errors or defects identified at this stage are corrected before moving to the finishing process.

4. Finishing

Once the shirt has passed all quality checks, it goes through a final pressing and folding process:

• The shirt is pressed to remove any wrinkles, giving it a polished appearance.
• The shirt is then neatly folded and prepared for packaging, ensuring it looks pristine when presented to customers.

Regal Rarities, this final stage is especially important because your customers expect a high-quality, well-presented product.

Conclusion: The Art of Sewing & Assembly In Regal Rarities

The sewing and assembly of your Cuban collar shirts is a meticulous process that requires a high level of precision, especially when working with linen and incorporating hand-embroidered Indian designs. Each step, from stitching the body to attaching the collar and finishing with the buttons and embroidery, ensures that the final product meets your brand’s standards of craftsmanship, authenticity, and quality. By focusing on durability, comfort, and aesthetic appeal, this process brings your unique, cultural shirts to life, making them a standout item in the market.