Custom Varsity Jacket Manufacturer

A varsity jacket is a wool body, leather sleeves, a striped rib and chenille patches. Substituting any of those with cheaper alternatives is obvious at arm's length, and buyers paying a premium price know exactly what a real letterman jacket feels like.

We manufacture custom varsity jackets with a wool-blend melton body, genuine or PU leather sleeves, striped 2×2 rib at collar, cuffs and hem, snap front, quilted lining and chenille or embroidered patches. Full wool, full leather and satin versions also available. For brands searching for a custom varsity jacket manufacturer that treats a 50-piece order like a real order, Mike Apparel samples first, produces in 2–3 weeks and delivers duties-paid.

Choosing the cloth for a custom jacket

Every jacket programme starts with a swatch card. These are the constructions we recommend for jackets; any of them can be dyed to Pantone and most can be washed or garment-dyed after sewing. If you are unsure, sample the varsity jacket in Melton wool 480 GSM body + PU leather sleeves first; it is the construction we recommend for the standard varsity.

Fit options for jackets

Pick a starting silhouette and we adjust from there. Blocks are graded XS to 3XL in US sizing, and size-set samples are available for brands that want to check the whole run. For a varsity jacket, we usually sample the classic letterman fit first and adjust from there.

• Classic letterman fit
• Oversized boxy varsity
• Cropped varsity (women's)
• Longline varsity

What is inside the seams

The stitch, rib, thread and hardware choices below are what separate a factory jacket from a promotional blank. All are standard on our runs. Start your varsity jacket tech pack with this line: striped 2×2 rib knitted to your colours (two or three stripes).

• Striped 2×2 rib knitted to your colours (two or three stripes)
• Snap front with metal snaps, or YKK zip
• Diamond-quilted lining with inner pocket
• Welt pockets with optional leather trim
• Leather sleeves fully lined and bagged

Embellishment and wash

Every embellishment listed here is produced in our own print, embroidery and wash departments in Sialkot. Panels are decorated before assembly where placement demands it. On a varsity jacket the most common request is chenille chest letter and back patch.

• Chenille chest letter and back patch
• Embroidered sleeve numbers and names
• Woven and leather patches
• Chain-stitch back embroidery
• Custom snap buttons

For a method-by-method comparison on jackets, read screen printing vs DTG vs embroidery.

Private label jackets

Your brand, not ours, is on the finished jacket. We sew in woven neck labels, size tabs and care labels to your artwork, attach hang tags and pack in branded poly bags or boxes. No Mike Apparel branding appears anywhere on the product. Our private label clothing page covers label options and minimums. A typical varsity jacket run carries a woven main label, printed care label and hang tag; letterman jacket programmes often add a woven hem loop.

Varsity Jacket minimum order quantity

Every custom jacket run starts at 50 pieces per design and colourway, sizes mixed however you like. Order more and the per-piece cost comes down, because cutting, sampling and setup are spread over a bigger run — that’s true whether you’re ordering jackets on their own or alongside other products. For reference, a varsity jacket run of 50 pieces in Melton wool 480 GSM body + PU leather sleeves with one embroidery and private labels is a typical starting spec.

What drives the final number is fabric weight, how much decoration is on the piece, and how many you order — we’ll walk you through all of it in your quote. Read custom jacket manufacturing cost if you want the detail on cost drivers before you ask. Varsity Jacket reorders skip the sample fee entirely, since the block and fabric lot are already on file.

Lead time and production process

The production process for a custom jacket runs in five steps. Sampling takes 7–10 days; bulk takes 2–3 weeks after approval; DDP air freight to the USA takes another four to seven days. For a varsity jacket the sample stage is where snap front with metal snaps, or YKK zip is confirmed on a real garment.

1. Brief and quote (24 hours)Send a tech pack, sketch or reference jacket with target quantity. We reply with fabric options, MOQ and a per-piece quote.
2. Pre-production sample (7–10 days)One jacket in your fabric, fit, colour and branding. Revisions until approved. Read about the sampling process.
3. Approval and depositSign off the sample and size set; 50% deposit reserves fabric and the production slot.
4. Bulk production (2–3 weeks)Cutting, sewing, wash, decoration, labelling, QC and packing in-house, with photo updates.
5. QC and DDP shipping (4–7 days by air)Inspection against the approved sample, then DDP delivery with duties paid. See our full timeline guide.

Made for US brands, shipped worldwide

Most of our jacket production ships to the United States, DDP, meaning duties, taxes and customs clearance are paid by us and included in the quote. Air freight lands in Miami or Dallas in four to seven days after the run ships; sea freight takes four to five weeks and costs less for larger orders. We also ship to the UK, Canada, Australia, the EU and the UAE. See streetwear manufacturing for USA brands and our DDP shipping page. A 50-piece varsity jacket order fits in a few cartons and clears US customs as one DDP consignment with a single commercial invoice.

Frequently asked questions

Related to the varsity jacket: custom jacket manufacturer, custom workwear jacket manufacturing, custom bomber jacket manufacturing, custom jacket manufacturing cost, what is a tech pack and do you need one to manufacture clothing?.

Last updated September 6, 2026 · Mike Apparel, Sialkot. Lead times reflect current factory capacity; confirm on your quote.