Custom Varsity Jacket Manufacturing: Complete Guide

The varsity (letterman) jacket is one of the most iconic American garments, and its streetwear revival has made it one of the most in-demand custom apparel products. This guide covers everything you need to know to manufacture premium custom varsity jackets.

Varsity Jacket Components

A traditional varsity jacket consists of multiple components that require different manufacturing expertise:

Body (Wool)

Melton Wool: The classic body fabric. Dense, firm, fully boiled wool:

Weight: 400-600 GSM

Colors: Most popular — Navy, Black, Forest Green, Burgundy, Royal Blue, Camel

Properties: Naturally warm, excellent stitch retention, holds shape well

Customization: Can be cut in any combination of two colors for color blocking

Wool-Blend: More affordable alternative:

80% Wool, 20% Nylon blend

Lower cost while maintaining classic look

Slightly less durable than full melton

Sleeves (Leather or PU)

Genuine Cowhide Leather: Premium finish, develops patina, long-lasting.

PU Leather: Vegan-friendly, consistent appearance, more affordable.

Color Options: Black (classic), Brown, White, Custom Pantone matching

Rib Trims

Elastic ribbed knit at collar, cuffs, and hem waistband:

Standard: 2-color striped rib (matches school/team colors)

Custom: Solid, multi-stripe, custom color combinations

Material: Cotton-acrylic blend, 400 GSM typical

Lining

Quilted Satin: Classic interior lining, warm feel.

Printed Satin: Premium option — print your design, artwork, or map on the lining interior.

Mesh: More breathable, less traditional look.

Closure

Snap Buttons: Traditional. Usually nickel, brass, or custom color.

Zipper: Modern alternative. YKK zippers for quality.

Customization Options

Chenille Patches

The signature decoration of varsity jackets:

Chenille letters: Athletic-style raised lettering

Chenille mascots/logos: Custom shape designs

Process: Woven chenille yarn sewn onto felt backing, then applied to jacket

Placement: Chest (left), back (large), sleeve

Embroidery

Direct embroidery on wool or leather panels

Best for text, names, numbers, smaller logos

Can be 3D puff embroidery for premium effect

Leather Embossing

Logo pressed into the leather sleeve

Subtle, premium finish

Works with custom dies

Screen Printing

On satin lining (interior art)

On wool body panels for bold graphics

Limited on leather panels

Custom Hardware

Snap button color and finish

Zipper pull style

Custom branded rivets

Build Specifications

**Standard sizing:**

XS through 4XL

Custom size ranges for youth collections

**Fit options:**

Classic/Relaxed: Traditional collegiate fit

Slim: More tailored, popular in streetwear

Oversized: Drop shoulder, very popular in current streetwear

Lead Time and Pricing

Varsity jackets are complex garments requiring multiple specialized components:

Lead time: 20-30 business days for bulk production

| Specification | MOQ 50 | MOQ 200 |

|--------------|--------|--------|

| Melton/PU Leather | $65-95 | $50-75 |

| Melton/Genuine Leather | $90-130 | $70-100 |

| Premium Wool/Leather + chenille | $110-160 | $85-130 |

**Additional customization costs:**

Chenille letters: $5-15 per letter

Custom chenille patch: $15-40

Custom printed lining: $8-15 per jacket

3D embroidery: $8-20 per placement

Contact Mughal Apparel for custom varsity jacket manufacturing. We produce for streetwear brands, universities, sports teams, and corporate clients. MOQ 50 pieces.

Custom Varsity Jacket Manufacturing: Complete Guide to Letterman Jackets