Front Zipper Construction
The front zipper has much less stretch than the Lycra body. Wrong zipper length or sewing tension can make the center front wavy. It can also cause puckering around the neckline. We set the zipper length based on the neckline depth and finished bra length. We also check whether it stays flat when the fabric is stretched.
Zipper options can include:
- Auto-lock zipper
- Inner zipper guard
- Top zipper cover
- Custom zipper length
- Branded zipper pull
Longline Hem Development
A standard sports bra pattern cannot simply be made longer. Extra length changes how the lower section fits around the torso. We adjust the body length, lower opening, and elastic tension together. This helps reduce rolling, flaring, or too much pressure at the bottom edge.
Mesh Racerback and Main Fabric Matching
Mesh and Lycra interlock may have different stretch and recovery. Using the same pattern ratio can cause puckering or pulling where the two fabrics meet. We check both materials during sampling. We then adjust the mesh panel size, seam tension, and joining construction to match their stretch behavior.
What Should Be Approved Before Bulk Production?
For this sports bra, we recommend locking these details with the approved sample:
- Zipper length and position
- Mesh quality and stretch direction
- Mesh panel shape
- Racerback width
- Longline body length
- Lower-edge tension
- Cup and lining construction
- Key seam positions
If the mesh, zipper, or body length changes later, we check the related fit points again. A change in one area can affect the tension in another.
