Custom Bike Riding Gear Manufacturing: Jerseys, Shorts, and Full Kit Guide

Cyclists are opinionated about their kit. Ask any serious rider about their jersey and they'll tell you exactly what fabric they prefer, how many back pockets they want, whether the zipper needs a garage to protect against wind, and what they think about the hem grippers. This is not a market where you can get away with generic sportswear construction and call it cycling gear.

The good news is that cycling apparel — when manufactured properly — is highly differentiated, commands good margins, and builds strong brand loyalty. The key is understanding what actual cyclists need and finding a manufacturing partner who can deliver it.

The Core Cycling Kit Products

Cycling Jerseys

The jersey is the centerpiece of any cycling kit. Here's what defines a good one:

Fabric — polyester with moisture-wicking treatment is the standard. Lighter weight fabrics (100-150gsm) work for summer; heavier or brushed options for cooler weather. Mesh panels in the underarm and back improve ventilation.

Cut — cycling jerseys use an aerodynamic cut that looks odd on a hanger but fits right on the bike. The back is longer than the front to cover the lower back when riding in a forward position. The shoulders are cut to wrap forward, and the sleeves are angled for the riding position. A factory that doesn't understand this will produce jerseys that look sloppy on the bike.

Back pockets — three back pockets is the road cycling standard. They need to be deep enough to actually hold things without losing them, wide enough to reach into with one hand while riding, and made from a slightly elastic fabric to accommodate stuffed pockets. Some brands add a fourth zippered security pocket.

Full-length zipper with garage — the "garage" is the fabric flap that prevents the zipper from catching wind and creating a buzzing sound at speed. This sounds like a minor detail until you've ridden 50km with a rattling zipper.

Hem grippers — silicon print or elastic gripper at the jersey hem keeps it from riding up. Not optional.

Printing — sublimation is the standard for cycling jerseys. All-over print, unlimited colors, excellent colorfastness. If a factory offers screen printing for cycling jerseys, that's a red flag — screen printing doesn't work on the stretch fabrics cycling jerseys require.

Bib Shorts and Cycling Shorts

The chamois (pad) is the most important and most variable element in cycling shorts. Get this wrong and you have an uncomfortable, unsellable product.

Chamois quality — the chamois is the padded insert in the crotch area that provides cushioning against the saddle. Quality chamois are multi-density foam, anatomically shaped for men's or women's anatomy, and have antibacterial treatment. Cheap chamois are flat, uniform-density foam that provide minimal protection and degrade quickly.

Compression grade — cycling shorts use compression to support muscle groups during pedaling. Specify compression level by fabric gsm and recovery percentage — don't let a factory make that call for you.

Bib vs waistband — bib shorts (with shoulder straps like suspenders) are preferred by serious cyclists because they stay in place better and don't compress the stomach. Waistband shorts are easier to deal with off the bike. Both have markets.

Gripper at hem — same principle as the jersey, silicon grippers keep the hem in place during pedaling.

Cycling Jackets, Gilets, and Accessories

A complete kit range should also consider:

Windproof gilets — lightweight vests that block wind but pack small enough to stuff in a back pocket. Technical fabric that balances wind resistance with breathability.

Waterproof cycling jackets — fully packable, high-viz options are popular. Requires seam sealing and technical laminate fabrics.

Arm warmers and knee warmers — tubes of compression fabric that can be added or removed during rides as temperature changes. Simple products, high perceived value.

Cycling caps — worn under helmets or as casual wear. A small-ticket item that drives brand visibility.

Sublimation Printing: The Non-Negotiable for Cycling

I want to spend some time on this because I still see brands trying to cut corners on printing for cycling gear and it consistently backfires.

Sublimation is the only viable printing technology for full-custom cycling jerseys and shorts. Here's why:

Cycling fabrics are polyester-based and stretchy. Sublimation dye bonds directly to polyester fibers at the molecular level. The result is a print that stretches with the fabric without cracking, fades very slowly even with repeated washing, and has no feel to it — the printed area has exactly the same texture as the unprinted fabric.

Screenprint or DTG on cycling fabrics produces prints that crack when stretched, feel heavy and stiff against the skin, and degrade rapidly with washing.

For sublimation to work, the fabric must be at least 75-80% polyester. White or very light base fabrics produce the best print results — sublimation doesn't print white, it works by the absence of dye. If your design requires white on a dark background, discuss this with your manufacturer because the approach is different.

Design files for sublimation need to be high-resolution (300dpi minimum) and designed in the specific template for each garment, accounting for seam placement and panel boundaries. A good manufacturer will provide these templates as part of the development process.

Mountain Bike vs Road Cycling: Different Products

One thing worth flagging — mountain bike (MTB) apparel and road cycling apparel have meaningfully different design priorities.

Road cycling gear optimizes for aerodynamics, lightweight, and packability. It's tight-fitting, technical, and often uses the most advanced fabrics.

MTB gear trends looser, more durable, and more casual in appearance. MTB jerseys often look closer to casual t-shirts and are made from heavier fabrics that handle brush contact and the occasional fall. MTB shorts are typically non-padded baggy shorts worn over a separate padded liner.

Know which market you're serving and build your spec accordingly.

Costs and MOQs for Custom Cycling Gear

Custom sublimation cycling jersey: $15-25 FOB depending on complexity and fabric specification.

Cycling bib shorts with quality chamois: $22-35 FOB. The chamois cost is a significant portion of the per-unit price — don't try to save money here.

Full kit (jersey + bib shorts) packaged together: $35-55 FOB.

Minimum order quantities start at 50 pieces per design colorway for our sublimation cycling products. Lead time from approved design to shipped goods is typically 30-45 days.

Check out our bike riding gear and sports wear catalog for reference products. To discuss your custom cycling program, get a free quote and we'll come back to you within 24 hours with detailed pricing.