A customer approached us to develop a 50 mm jacquard elastic underband for a sports bra. She already had a sample, but the logo lettering looked unclear and became distorted when the elastic was stretched. She wanted to keep the original logo design, width, and material composition.
After reviewing the existing sample, we selected finer yarn and reduced the webbing thickness from 2.0 mm to 1.5 mm. The revised underband showed clearer lettering and less distortion while maintaining approximately the same stretch and tension.
We then produced a small batch for the customer to test. She later confirmed there were no issues, and the project moved into bulk production.
We received an RFQ through our website from a customer developing a sports bra underband with a two-color jacquard logo. She already had a sample from another supplier, but the lettering was unclear and became more distorted when the elastic was stretched. She shared photos and short videos showing the problem.
The underband was 50 mm wide and 2.0 mm thick. She wanted to keep the original logo design, width, and material composition, so changing the artwork or making the band wider wasn’t the solution she was looking for.
The photos and videos showed us the problem, but they couldn’t tell us enough about the yarn and construction. We asked her to send the physical sample so we could examine how the logo had been woven.
When we examined the sample, we found that the yarn was relatively coarse for the lettering detail. The 2.0 mm thickness was another part of the existing construction we needed to reconsider. We decided to work on the yarn and webbing structure rather than change her logo design.
When we planned the revised sample, we didn’t want to change the materials simply to make the logo clearer. The customer’s existing underband already had the stretch, hand feel, and support she wanted. Those properties were not the reason she approached us.
Changing the material type or composition would have introduced more variables into the project. Even if the logo improved, the customer might then need to spend additional time checking whether the new elastic still provided the same fit and support in her sports bra. We wanted to avoid creating a new development problem while solving the original one.
We therefore kept the same materials and material ratio, but selected finer yarn specifications for the jacquard construction. We also reduced the webbing thickness from 2.0 mm to 1.5 mm, keeping the original 50 mm width and two-color logo design.
We made these adjustments together. The finer yarn was selected to improve the definition of the lettering, while the reduced thickness addressed another limitation we had identified in the original construction. We worked on both specifications rather than asking the customer to change her artwork.
When we compared the revised sample with the original, the difference was visible. The original lettering had looked blurred and became more distorted under stretch. On the revised underband, the lettering was clearer and retained its shape better when stretched. The overall stretch and tension also remained close to those of the original sample.
The revised sample gave us a clearer logo, but it was also 0.5 mm thinner than the customer’s original underband. Before moving forward, we discussed whether she wanted to keep the original 2.0 mm thickness or accept the revised construction.
We explained that the original logo lettering was difficult to reproduce clearly with the thicker construction we had examined. If she wanted to retain that thickness, we would need to reconsider the size and proportions of the lettering. Larger letters would give us more room to reproduce the details in the jacquard weave, although the result would still need to be confirmed through sampling.
The other option was the revised 1.5 mm underband. It kept her original two-color logo design, 50 mm width, and material composition, and the new sample had already shown clearer lettering with less distortion under stretch.
The customer chose the 1.5 mm version. Keeping the original logo design was more important to her than retaining the original thickness.
After the customer chose the 1.5 mm underband, we produced a small batch of the revised jacquard elastic for her to evaluate before bulk production. This was the next stage of the project after we had compared the new sample with the original.
Our sample comparison had shown that the lettering was clearer and the logo held its shape better when stretched. The overall stretch and tension were also close to the original underband. These were encouraging results, but they did not answer every question about how the revised elastic would work in the customer’s sports bra.
The original underband had already met her expectations for stretch, hand feel, and support. Although we had kept the same materials and composition, reducing the thickness from 2.0 mm to 1.5 mm was still a change to the construction. We could compare the two versions as a webbing manufacturer, but the customer needed to decide whether the revised version was suitable for her finished product.
After evaluating the small batch, she told us there were no issues with the revised underband. Following that feedback, we arranged bulk production using the agreed 1.5 mm construction.
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