How To Start A Mens Underwear Brand In The UK

222. Starting a men’s underwear brand in the UK is one of the most accessible entry points into the fashion industry. Compared to many other types of clothing, underwear requires less fabric, is cheaper to produce, and is easier to store and transport.

Despite this, it is also a highly specialised product that requires the right knowledge, materials and manufacturing processes to achieve a professional result.

If you are new to the clothing industry, this guide will walk you through the key steps involved in launching a successful men’s underwear brand.

Step 1: Understand the Opportunity in Underwear

Men’s underwear is a strong niche within fashion, with consistent demand and relatively low barriers to entry.

Advantages include:

  • Lower production costs compared to outerwear
  • Smaller, easier-to-manage products
  • Strong repeat purchase potential
  • Opportunities to build niche brands

Many successful startup brands begin in niche markets like underwear rather than trying to compete in broader fashion categories.

Step 2: Choose Your Product Type

Men’s underwear includes a range of styles, each with different construction requirements.

Common categories include:

  • Boxer briefs
  • Briefs
  • Trunks
  • Loungewear and sleepwear

Sleepwear can be divided into:

  • Woven garments (e.g. cotton pyjamas), which can be made in standard factories
  • Stretch garments, which require specialist machinery

Choosing your product type early will determine your design and manufacturing approach.

Step 3: Understand Fabrics and Comfort

Underwear must be comfortable, durable and suitable for everyday wear.

Fabric selection is critical and typically includes:

  • Cotton and cotton blends
  • Stretch fabrics with elastane
  • Breathable and moisture-managing materials

Unlike outerwear, underwear sits directly against the skin, so poor fabric choices or construction will result in an uncomfortable product.

Step 4: Learn About Specialist Construction

Men’s underwear cannot be made properly using standard garment construction.

Specialist machinery is required, including:

  • Flatlock (flatstitch) machines
  • Coverstitch machines

These machines allow seams to stretch with the fabric while remaining strong and comfortable.

Attempting to produce underwear using standard machinery will result in poor-quality garments that are uncomfortable and unlikely to sell.

Step 5: Develop Patterns and Samples

Accurate pattern cutting is essential for underwear.

Poorly cut patterns will lead to:

  • Poor fit
  • Lack of support
  • Discomfort

Before production, you will need to:

  • Create patterns
  • Produce samples
  • Test fit and comfort
  • Refine your designs

Many startups base their initial designs on existing garments that fit well, using them as a reference point to reduce trial and error.

Step 6: Understand Minimum Order Quantities (MOQs)

One of the biggest challenges in starting an underwear brand is finding manufacturers willing to produce small quantities.

Many specialist underwear factories require high MOQs, which can be difficult for startups.

Some common mistakes include:

  • Using non-specialist factories
  • Compromising on machinery and construction
  • Producing low-quality garments

Because underwear is worn next to the skin, quality is critical. Poor construction or fit will quickly damage your brand.

Step 7: Manufacturing in the UK vs Overseas

Manufacturing decisions are important for any startup brand.

For beginners, UK production offers:

  • Better communication
  • Easier quality control
  • Lower risk

However, for larger quantities, offshore production can sometimes be more viable—provided that:

  • Patterns and samples are developed correctly first
  • You work with experienced manufacturers

A cautious approach is to begin with UK production and move overseas once your product is fully developed.

Step 8: Start Small and Build Your Brand

Launching with a small collection allows you to:

  • Test your designs
  • Refine your fit and quality
  • Manage your budget

Underwear brands often succeed by focusing on:

  • Fit and comfort
  • Fabric quality
  • Branding and identity

Over time, you can expand your range and scale production.

Common Mistakes When Starting a Men’s Underwear Brand

  • Using factories without specialist machinery
  • Ignoring fit and comfort
  • Choosing poor-quality fabrics
  • Producing large quantities too early
  • Underestimating the importance of pattern cutting

Avoiding these mistakes will significantly increase your chances of success.

How We Can Help

We have experience working with startup underwear brands, helping them develop production-ready garments.

Our services include:

  • One-to-one startup consultations
  • Pattern cutting
  • Product development
  • Sampling
  • Tech packs
  • Manufacturing advice

Whether you are launching a small underwear line or building a larger brand, we can help guide you through every stage of the process.

Frequently Asked Questions

How much does it cost to start a men’s underwear brand?

Costs vary depending on your designs, fabrics and production quantities. Underwear is generally more affordable to produce than outerwear, making it a good option for startups.

Do I need specialist machinery to make underwear?

Yes. Underwear requires flatlock and coverstitch machines to produce seams that are both strong and comfortable.

Can I use a normal clothing factory?

It is not recommended. Most standard garment factories do not have the specialist machinery needed to produce high-quality underwear.

What fabrics are best for men’s underwear?

Cotton blends and stretch fabrics are commonly used due to their comfort, breathability and flexibility.

Can The London Pattern Cutter Help Me Start a Men’s Underwear Brand?

Yes. We help startup underwear brands with pattern cutting, sampling, product development, tech packs and manufacturing guidance, helping you bring your ideas to market.

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