From idea to
finished garment.
Made in the USA. Built for longevity. Full-stack apparel production — pattern to labeled, packaged garment — for kids and adults, in every size.
The Production Blueprint
Eight phases.
Zero handoffs.
Every BHLANKS program runs the same disciplined path — from qualification to reorder — with one team accountable end to end.
Client Qualification
Determine whether the brand, project scope and volume are a fit for BHLANKS full-stack production.
Key Actions
- Intake call to understand the brand, product category and stage
- Confirm kids, adults or both, and full size range
- Review target volume, MOQ range and desired timeline
- Clarify budget bands, compliance needs and delivery dates
- Confirm starting point: pure idea or existing tech packs
Deliverables
- Qualified project brief
- Scope and feasibility confirmation
- Next-step roadmap
Design & Technical Intake
Translate the concept or existing tech packs into complete, production-ready technical documentation.
Key Actions
- Collect sketches, references, tech packs and fit standards
- Develop or refine the tech pack: construction, POMs, trims, labels
- Pattern making and grading across the requested size range
- Confirm fabrication: French terry weight, blend and finish
- Lock artwork, print placement and labeling requirements
Deliverables
- Final tech pack
- Graded patterns
- Bill of materials
- Trim and label spec
Quoting & Production Proposal
Deliver transparent, relationship-driven pricing and a realistic production timeline.
Key Actions
- Cost fabric, knitting, cut & sew, dye, print, trims and packaging
- Build tiered pricing across volume breaks
- Map the full production calendar with milestone dates
- Identify risk points and alternative material paths
Deliverables
- Line-itemized quote
- Volume tier pricing
- Production timeline
- Formal proposal
Contracting & Payment Setup
Formalize the partnership with clear terms, schedules and payment structure.
Key Actions
- Issue production agreement and terms of service
- Confirm deposit, milestone and balance payment schedule
- Lock quantities, size curve, delivery dates and tolerances
- Set communication cadence and points of contact
Deliverables
- Signed production agreement
- Payment schedule
- Confirmed purchase order
Sampling & Approval
Prove the garment physically before a single yard of bulk fabric is committed.
Key Actions
- Knit or source fabric for proto and lab dips
- Produce proto sample, then fit sample, then pre-production sample
- Fit sessions and pattern corrections across the size curve
- Approve color standards, wash, hand-feel and shrinkage
- Approve labels, tags, print strike-offs and packaging
Deliverables
- Approved PP sample
- Signed-off lab dips
- Final size spec
- Sealed sample
Bulk Production
Execute the approved sample at volume with in-line quality control at every station.
Key Actions
- Circular knitting of French terry and jersey to spec
- Garment dye, wash and finishing to approved standards
- Cutting, bundling and full cut & sew production
- Printing, embroidery, labeling and tagging
- In-line and end-line QC against the sealed sample
Deliverables
- Bulk garments produced
- QC inspection reports
- Measurement audit
- Shortage report
Packaging, Shipping & Delivery
Deliver finished, labeled, retail-ready goods on schedule.
Key Actions
- Final press, fold and individual polybagging as specified
- Hang tags, care labels, barcodes and compliance labeling
- Carton packing, master labeling and packing lists
- Freight coordination, DC routing or direct-to-brand delivery
Deliverables
- Retail-ready packed goods
- Packing list and carton manifest
- Shipping documentation
Post-Production & Client Growth
Turn a first run into a repeatable, improving, long-term production program.
Key Actions
- Post-production debrief on fit, quality and timing
- Archive patterns, specs and sealed samples for instant reorder
- Cost engineering for the next run at higher volume
- Plan the next drop, extensions and new categories
Deliverables
- Production debrief
- Archived spec library
- Reorder pricing
- Growth roadmap
Material & Construction
Looped inside.
Smooth outside.
French terry is built with a clean knit face and an unbrushed looped interior. That structure holds shape, breathes, and resists the pilling and collapse that ruins brushed fleece — which is why it wears in instead of wearing out.
- Garment dye
- 100% cotton, dyed as a finished garment for depth and lived-in hand.
- Stitch quality
- Reinforced seams, clean coverstitch, consistent SPI across the run.
- Labeling
- Woven main labels, care and size labels, hang tags, retail compliance.
- Full size range
- Kids 2–12 and adults, graded across the complete size curve.
Collection Archive
Terry Hoodie
All sizes · French terry · Garment dyed · 100% cotton · Made in USA
Terry Crewneck
All sizes · French terry · Garment dyed · 100% cotton · Made in USA
Terry Short
All sizes · French terry · Garment dyed · 100% cotton · Made in USA
Terry Pant
All sizes · French terry · Garment dyed · 100% cotton · Made in USA
Why BHLANKS
Premium construction & materials
Heavyweight French terry, 100% cotton garment dye, clean stitch architecture and finishing standards built to survive years of wear — not one season.
Relationship-driven pricing
Deep, long-standing LA manufacturing relationships let us hold real Made-in-USA quality at pricing that keeps your margins healthy.
Full ownership of the process
Pattern, knit, dye, cut & sew, print, label, pack. One team, one accountability line, from first sketch to labeled carton.
Built for long-term partners
Archived patterns, sealed samples and cost engineering make every reorder faster, tighter and better priced than the last.
Start a Project
Tell us what
you're building.
This is Phase 01 — Client Qualification. Share the essentials and we'll come back with feasibility, scope and next steps.