Custom Cycling Jersey Manufacturing: Performance Fabrics and Design Guide

Cycling jerseys are among the most technically specific garments in sportswear. The sport creates a unique set of requirements — an aerodynamic posture that means the front and back of the jersey are cut completely differently, intense UV exposure that demands specific fabric protection, and sweat management over potentially very long durations of exercise.

We produce custom cycling jerseys for professional clubs, cycling academies, sportswear brands, and corporate team-building programs. The technical requirements are consistent across all applications, even though the design aesthetic varies widely. Here is everything you need to know to produce a quality custom cycling jersey.

The Unique Construction of a Road Cycling Jersey

The biggest thing that separates cycling jerseys from other custom jerseys is how the body is constructed to account for riding position.

When a cyclist is in their riding position (leaning forward over the bars), the back of the jersey needs to be longer than when standing upright. If you make a jersey with equal front and back length and put it on a cyclist in their riding position, the back rides up and exposes the lower back, while the front bunches uncomfortably.

A proper road cycling jersey has a longer back panel — typically 5 to 10 cm longer than the front. This length compensation is called the "riding hem" or "cycling hem," and it is one of the first things experienced cyclists check when evaluating a jersey. Getting this wrong is an immediately obvious quality failure.

Cycling jerseys also use a full-length front zipper (for ventilation control during varying intensity efforts) and typically have a zippered pocket or open-top pockets at the lower back hem — a signature cycling design element used for storing food, a phone, or a jacket while riding.

Fabric Specifications for Cycling Jerseys

Main body fabric: 100% polyester knit, 100 to 150 GSM. Cycling jerseys are among the lightest garments in the sportswear category — you want as little fabric weight as possible while maintaining coverage and structure. Lightweight polyester jersey (not mesh, not heavy interlock) is the standard.

Moisture management: Cycling generates intense and sustained sweat. The fabric must move moisture away from skin rapidly. Specify a moisture-wicking treatment and test it — the fabric should spread moisture rapidly across its surface for fast evaporation, not just repel it.

UPF rating: Cyclists spend hours in direct sunlight. A UPF 50+ rating is standard for quality cycling jerseys. Verify this with your fabric supplier.

Stretch and recovery: The body panels need enough stretch to allow full arm and torso movement, but with sufficient recovery to maintain compression and aero fit. 4-way stretch polyester with 8 to 12% spandex is typical.

Grippers (silicone elastic hem): The bottom hem of a cycling jersey is almost always finished with silicone gripper elastic — a wide elastic band with a silicone pattern printed on the interior that prevents the jersey from riding up during riding. Specify gripper width (typically 3 to 5 cm) and the silicone pattern (typically a wave or stripe print). This detail is critical for function and is one of the markers customers look for in quality cycling apparel.

Side Panels and Mesh Inserts

Many cycling jerseys incorporate a different, more open-weave fabric in the side panels. This serves two purposes: additional ventilation in the areas that heat up fastest, and potential weight savings.

Mesh or micro-perforated panels on the sides and underarm areas are a functional upgrade that also creates visual interest in the design. If you are using side panels in a different fabric, specify:

Sublimation Printing: The Only Choice for Cycling Jerseys

Custom cycling jerseys are almost universally produced using sublimation printing. The combination of lightweight polyester fabric, complex full-color designs (cycling team kits tend toward bold and visually complex), and the need for prints that do not add weight or restrict the fabric's technical properties makes sublimation the clear choice.

With sublimation you can achieve:

For cycling team kits in particular, sublimation-printed jerseys are the standard from recreational club level all the way to professional teams.

Design Considerations for Cycling Team Kits

A complete cycling team kit typically includes jersey, bib shorts (or standard shorts), and optionally a wind jacket and arm warmers. For a cohesive kit, all pieces need to be designed and produced together with consistent sublimation printing.

Jersey design zones: The main body front and back, the sleeves, the collar area, and the pocket area all have different design opportunities and constraints. The pockets are typically a neutral color (white or black) because adding complex graphics to a functional pocket area can look cluttered.

Sponsor integration: Cycling kits heavily feature sponsor logos. Define sponsor placement zones carefully — typically main sponsors on the front chest, secondary sponsors on the sleeves and back, smaller sponsors on the lower back pocket area. Provide your clients or sponsors with a kit placement diagram.

Collar design: Most cycling jerseys use a narrow banded collar (2 to 3 cm) with a small zip at the rear for ventilation adjustment, or a full-length front zipper that extends to the collar. Define collar construction in your tech pack.

Number placement: If the kit is for a racing team, race numbers are typically pinned on separately (not printed on the jersey), so you do not need to account for number placement on the jersey itself. However, some training or recreational kits include a front chest number panel.

MOQ and Turnaround for Custom Cycling Jerseys

Cycling jerseys with full sublimation printing are accessible even at modest quantities. At Mughal Apparel, our minimum order for custom cycling jerseys is 50 pieces, which covers a small cycling club or team.

For club orders with individual name personalization, we typically run the entire set simultaneously to ensure color consistency across all jerseys.

For brands producing retail cycling apparel (rather than specific team kits), we can produce larger runs with consistent quality across sizes and colorways.

If you are developing a cycling jersey or complete cycling kit, check out our bike riding gear and sports wear catalog for examples. Then get a free quote with your design requirements — we respond within 24 hours.