How to design and produce a unique custom jacquard elastic waistband from scratch.
Welcome to Paluna Textile, your creative elastic webbing hub. Here is a tutorial to show you how to design a high-quality jacquard elastic band step by step. Briefly, you will spend 3 minutes in this post and have below key points.
1. Requirements analysis based on the specific use
2. Yarn and elastic thread selection in elastic waistband
3. Weaving Pattern and texture comparison
4. Jacquard elastic design and drawing settings
5. Jacquard elastic sample making
6. Sewing and model testing
In this case, we will take elastic waistband for men’s underwear boxer briefs as a tutorial. Below is size chart of men’s brief boxer size range from S to 5XL.
Usually, if you are above the upper limit of waist size, we recommend you go up to the next size.
Step 1, Requirements analysis based on the specific use
If you want to create a new style of men’s boxer briefs, you need to finish the design in your mind first, before you sew them with elastic bands and fabrics, a design and calculation on paper is necessary and helpful.
For example, you plan to produce 2000 pieces of men’s boxer briefs in sizes L and XL, imagine 1000 pieces of each size. Both are made with elastic waistbands in size 1.5 inches. Now you can calculate the quantity from above chart, it is 38*1000 plus 42*1000, 80000 inches of elastic band in total, equal to 2230 yards.
But which type of yarn material would be the best choice for elastic waistbands? In the next step, it will show the popular yarn types in elastic waistbands for boxer briefs use.
Step 2, Yarn and elastic thread selection for elastic underwear waistand
These men’s boxer briefs contact the human body directly, therefore, comfort and skin-friendly performance should come first in yarn and elastic thread selection.
Nowadays, the popular yarn of elastic waistbands includes nylon and silky nylon. Both such nylon yarns are excellent in sweat absorption, however, the silky nylon looks much high-end quality and ultra-smooth feel. Moreover, 70D-100D silky nylon yarn can be woven in a very fine texture and show perfect detailed features of custom patterns. This is why we strongly recommend it as warp yarn.
In elastic thread choice, spandex is the top choice and much better than latex as it is skin-friendly, so you can follow most buyers’ preferences.
Step 3, Weaving Pattern and texture comparison
There are three main texture patterns in elastic band weaving, plain, rib, and twill. In twill texture, the warp segment is usually longer than that in plain and rib texture.
If we make a twill texture on the inner side of the elastic waistband, it can enhance sweat absorption performance. However, twill texture may cause yarn loops after a period of use. Below are the detailed comparisons between twill and plain textures.
So you can define separately on each side of the elastic waistband and follow your preference in weaving texture and pattern.
Step 4, Jacquard elastic design and drawing settings
Before this step, you have set the webbing size to 1.5 inches, now you can define other settings of an elastic band on paper including sewing margin, logo positioning, repeating, or the loop length of patterns.
If you want the logo in the perfect center of the elastic waistband, we recommend you add a positioning mark and make a little more length wastage for cutting and sewing. If not, you can ignore the positioning issue, and set a suitable repeating length of the pattern.
In logo and pattern positioning, you should always define at least 3-5mm as the bottom margin for sewing elastic waistbands and fabrics. Otherwise, part of the logo or pattern would be covered by fabric after sewing.
Step 5, Jacquard elastic waistband sample production
Once you confirm the yarn type and jacquard webbing design, Paluna will input the design drawing to the computer of the jacquard weaving loom to start sample production.
Some type of yarn needs after-dyeing and pre-shrinkage processing, and it usually costs 3 days in finishing.
Before shipping, our QC staff will inspect items one by one according to the industrial quality standards. After the quality inspection is finished, the sample will be shipped by express to our client’s doorstep within 5-7 days.
Step 6, Sewing and model testing
When receiving the finished sample, you can cut the elastic waistband into designated lengths, in this case, it is 38″ and 42″ men’s boxer briefs waistbands.
Now you finish all the steps of how to design a personalized elastic waistband.
By the way, you can also leave all these jobs to an expert from Paluna via paluna@palunawebbing.com or via WhatsApp +86 15961678969, we are happy to offer jacquard elastic design service and sample development for you, the design is always free.
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