Introduction
Activewear size grading is a critical process that ensures consistent fit across all sizes. In Part 4 of our series, we dive into advanced topics including OEM (Original Equipment Manufacturing), ODM (Original Design Manufacturing), MOQ (Minimum Order Quantity), quality control, and manufacturing best practices. This guide is essential for brands looking to scale production while maintaining premium quality. luckyyoga, a leading manufacturer of premium activewear, leverages these principles to deliver exceptional products.
Key Factors in Activewear Size Grading
Body Measurement Grading
Grading involves incrementally increasing measurements from a base size. Key points include:
Fabric Stretch and Recovery
Activewear fabrics (e.g., nylon/spandex blends) have significant stretch. Grade increments must account for stretch percentage to avoid over-grading. For example, a fabric with 30% stretch may require smaller grade increments than a non-stretch fabric.
Size Chart Standardization
Aligning with industry standards (e.g., ASTM D5585) ensures compatibility. luckyyoga uses data-driven size charts based on thousands of body scans to optimize fit.
OEM and ODM Considerations
OEM (Original Equipment Manufacturing)
OEM involves producing garments based on a brand's specifications. For size grading, brands must provide detailed grade rules. Common mistakes include:
ODM (Original Design Manufacturing)
ODM allows brands to choose from existing designs. Here, size grading is pre-set by the manufacturer. Brands should request grade rules and test samples for fit.
MOQ and Its Impact on Size Grading
MOQ (Minimum Order Quantity) affects how many sizes can be produced. Higher MOQs allow more size options, but lower MOQs may limit size runs. Optimizing MOQ requires:
Quality Control in Size Grading
Pre-Production Samples
Before bulk production, manufacturers create samples in multiple sizes. Quality control checks include:
In-Process Inspection
During cutting and sewing, random samples are pulled to ensure consistency. Common issues:
Final Inspection
AQL (Acceptable Quality Level) standards are applied. For premium activewear, AQL 2.5 is common. luckyyoga implements a 4-point system to grade defects.
Manufacturing Best Practices
Pattern Grading Technology
Advanced CAD systems automate grading, reducing human error. 3D simulation allows virtual fit testing before production.
Collaboration with Manufacturers
Regular communication ensures alignment. Provide clear grade specs and size charts. Use a fit session to approve final grades.
Documentation
Maintain a grade rule table for each style. Include:
Common Mistakes in Size Grading
How luckyyoga Approaches Size Grading
luckyyoga follows a rigorous process:
This approach reduces returns and enhances customer satisfaction.
FAQ
1. What is the difference between OEM and ODM in activewear?
OEM means you provide the design and specifications, and the manufacturer produces it. ODM means you choose from the manufacturer's existing designs, which may have pre-set size grading.
2. How does fabric stretch affect size grading?
Stretch fabrics require smaller grade increments because they accommodate more body shapes. Overgrading can lead to loose fit. Manufacturers often test stretch recovery to set appropriate grades.
3. What is a typical MOQ for custom size grading?
MOQ varies by manufacturer. For luckyyoga, MOQ can be as low as 100 units per style, but custom grading may require higher quantities to offset pattern costs.
4. How do I ensure consistent quality control in size grading?
Implement a three-stage QC: pre-production sample approval, in-process inspection, and final AQL inspection. Use detailed grade rule documents and fit tests.
5. Can I use the same grade rules for different activewear styles?
No. Each style (e.g., leggings vs. sports bras) has different body coverage and fabric requirements. Grade rules must be tailored to the specific garment type.
