Paste your Google Webmaster Tools verification code here

Contact Us

Mens Underwear Patterns and Samples

Mens Underwear Index

Mens underwear purchasing has long been thought to be a barometer for wider economic performance throughout the economy as a whole. When the bottom falls out of the underwear market, then you can bet the economy is going to follow not far behind.The Men`s Underwear Index (MUI) was used by Alan Greenspan in the 1970`s to forecast future economic developments.

PHONE – 07905-965-305 ( BILL )


To completely contradict Greenspans economic theory – In recent years there has been a massive  increased demand for mens underwear and loungewear.  Despite this extra demand, there are very few specialists in mens underwear pattern making, sampling, or production in the UK.

Most mens underwear factories have very high minimum order quantities ( MOQ ). This makes it extremely difficult for small startup brands who just need minimum quantities to start with.

Often these new businesses have to get their patterns made by a non-specialised pattern cutter and sample machinist. Then the production is done by ordinary factories without the specialist machinery necessary to make the garments correctly.

This all adds up to make the final product extremely poor. And the last thing that you want to be made this poorly is underwear. The patterns, the fabrics,the threads, the trims, and the construction all need to be perfect.

You cant make mens underwear using normal seam construction, or using poorly cut patterns, because they would be extremely uncomfortable.

Sportswear and underwear are closely related products and many sportswear items are now worn as underwear. Much of the specialist machinery used to make sportswear is also used for mens underwear, as both clothing types have similar functions and requirements.

While my background has been mainly in tailoring and outerwear patterns, I find that underwear, along with sportswear and swimwear, is an interesting area of pattern cutting to explore .

Mens underwear styles

Mens underwear comprises a relatively narrow range of styles, although this is changing as they become more of a fashion item. Styles include :-

  • Briefs
  • Low rise briefs
  • High rise briefs
  • Boxers
  • Boxer briefs
  • Y Fronts
  • Trunks
  • Jockstraps
  • Longs
  • G Strings
  • Vests
  • Singlets

 Variations in style

There are in fact many variations that can be designed. Boxers may have an encased waistband with a fly opening, or a sewn on elastic waistband without a fly.They can be in a stretch fabric or a rigid one. Modern briefs generally have a contour pouch with or without a centre front seam. Or they may have a traditional crossover fly.

There are a few recognised brands such as Calvin Klein, Jockey and Sloggi that have a large part of the market, and there have been a number of established designer brands jumping onto the band wagon.

There is a lot of room for small startup brands to establish their own line. It is often in  these niche markets, rather than in general fashion where the greatest potential for success lies within the clothing industry.

There is far less competition and the amount of money required to bring to market a mens Boxer brief is considerably less than for a shirt or a jacket for example. As long as you can find a factory to produce small orders.

Because the garments are relatively compact they are cheap to make , store and transport. The potential for problems are also lower than for general fashion.

Most large underwear factories will only produce underwear, in contrast to most normal garment factories that will produce a wide range of types of garments. It is not advisable to have a normal clothing factory make mens underwear as special machinery is required, notably flatstitch and coverstitch machinery.

What is Flatstitch ?

Flatstitch is essential for many types of underwear and sportswear construction. It is a seam that joins two pieces of fabric together by butting the two edges together and oversewing  with a zig-zag stitch. This  allows the seam to lay flat, providing more comfort for the wearer.

What is Coverstitch ?

Coverstitch is used extensively for hems in underwear and sporstswear. It allows for a great amount of stretch to hems without breaking the stitching. The coverstitch gives a twin needle top stitch finish on the outside, while covering the inside fabric edge with a zig-zag overlock stitch.

Offshore production ?

While I do not normally advise Clients to use offshore production, this is one area that could be an exception if there are fairly large quantities involved.  I would still always advise using U.K. production initially though.

Getting started

Pattern for mans boxer brief

If you are interested in starting your own line in mens underwear, or if you are already established, I would suggest looking round at the existing styles and in magazines. Get together a few ideas and if necessary purchase some garments that you like. These can be used as a basis to make your own styles. Although it may be regarded as “cheating” it does help to prevent trial and error. Make some rough sketches of what you want along with any necessary information, then give me a ring and I will try to help produce your garment.

We can help you at every stage of the way, from the initial concept, design,sourcing fabrics and trims, through to production. If you just want some advice or mentoring, then we can help you there too.

Startup Wokshop

We offer a concise   1-1 Startup workshop for anyone who is thinking of starting a fashion brand, or is just starting out. This can be conducted face to face, or via Skype. Please ring for details.

PHONE – 07905-965-305 ( BILL )



Helping fashion startups since 1984