Custom Scrubs: Design, Materials, Branding & Packaging

Whether you’re outfitting a hospital system, a private clinic, or a retail brand, our custom scrubs program lets you control fabric performance, fit, colors, trims, pockets, branding, packaging, and compliance—end to end.

1) How Our Custom Program Works

Brief & Target Use
Tell us who will wear the scrubs (ER, OR, outpatient, dental, vet, retail), wash cycles, budget, and preferred timeline.
Fabric Selection & Testing
We shortlist 2–4 fabric options by hand-feel and performance; send swatches; run basic tests (shrinkage, colorfastness, pilling).
Style & Pocket Layout
Pick a base style (top/pant/set/jacket), necklines, fits, and pocket maps. We share tech packs or co-create them.
Branding & Colors
Approve Pantone colors, logo placements (embroidery / print / labels), and size label system.
Sample & Fit Approval
Receive pre-production sample with full trims for try-on; confirm grading across sizes.
Bulk Production & QC
We implement AQL inspections at cutting, in-line sewing, and final packing.
Packing & Shipment
Choose retail or bulk packing; confirm carton spec and pallet plan.

2) Fabric & Performance Options

Choose by hand-feel, durability, and compliance needs:

Core Blends
- 65/35 Poly-Cotton (Twill/Plain): durable, easy-care, cost-effective.
- 72/25/3 Poly-Rayon-Spandex: drapey, soft, premium hand.
- 90/10 Polyester-Spandex (4-way stretch): lightweight, quick-dry, athletic comfort.
Performance Finishes
- Antimicrobial/Antibacterial (additive finishes where allowed).
- Moisture-wicking & Quick-dry.
- Stain-release / Soil-repellent.
- Anti-static for specific environments.
- Fluid-repellent / DWR (Durable Water Repellent) for splash zones.
Weight & Hand-Feel
- 130–180 gsm typical; we balance opacity, drape, and climate.
- Brushed back for winter warmth; cool-touch weaves for hot climates.
Care Standards
- Designed for industrial laundry or home machine wash; specify wash temp, tumble settings, and required colorfastness.

Tip: If your team runs long shifts or moves a lot, prioritize 4-way stretch with moisture-wicking.

3) Fits, Silhouettes & Construction

Build a consistent look across departments while keeping comfort:

Tops
- V-Neck / Mock-Wrap / Zip-Front / Mandarin Collar
- Side vents or curved hem for mobility
- Princess seams (women), straight cut (unisex/men)
Pants
- Jogger Scrubs (ribbed cuffs), straight-leg, boot-cut
- Waist options: elastic, drawcord, half-elastic with internal tie, yoga-style knit waist
- Gusseted crotch for extra mobility (optional)
Jackets
- Warm-up Jackets: zip front, knit cuffs, stand collar optional
Maternity / Plus / Petite & Tall
- Dedicated blocks to ensure comfort and proportion.
Seams & Stress Points
- Bar-tacks at pocket corners and side vents; double-needle topstitching where needed.

4) Pocket Maps & Utility Features

Organize tools without bulk:

Tops
- 1–3 patch pockets; optional chest pocket; pen slot; ID loop; badge clip tab.
- Hidden zip pocket for valuables.
Pants
- Slash hand pockets; 1–2 cargo pockets; back pockets with flaps or bartacks; internal phone sleeve.
- Key loop or D-ring for cards/keys.
Specialized
- Dental/vet: smaller instrument sleeves; water-resistant pocket bags by request.

5) Colors, Trims & Aesthetics

Color Systems
- Pantone-matched solids; department color-coding; contrast piping or bartacks for brand accents.
- Heathered looks via mélange yarns (on select blends).
Trims
- Zippers (coil/vislon), snaps, rib cuffs (poly-spandex, cotton-spandex), woven drawcords.
- Reflective tape for night/home-care routes (optional).
Labeling
- Woven main label, size label, care label, and optional private brand label sets.
- Heat-transfer labels for tag-free comfort.

6) Branding & Logo Applications

Pick methods by your artwork style and wash conditions:

Embroidery: classic, premium; best for logos with solid fills.
Silkscreen Print: bold, cost-effective for larger graphics.
Heat-Transfer / DTF: detail-rich, smooth surface; great for small runs or multicolor.
Woven/Printed Badges: removable brand patches for universal garments.

Placement ideas: left chest, sleeve, back yoke, pant thigh/cargo flap. We provide strike-offs before bulk.

7) Size Range, Grading & Fit Sets

Standard Ranges
- Women: XXS–3XL (extendable) | Men/Unisex: XS–5XL (extendable).
- Petite / Tall inseams for pants; maternity panels with elastic support.
Fit Testing
- Send a size run sample pack for frontline try-ons; collect notes; lock final grading.
Measurement Tolerance
- Typical ±1 cm tops, ±1.5 cm pants; can tighten for premium lines.

8) Compliance, Testing & Documentation

Colorfastness to washing, perspiration, crocking
Dimensional stability (shrinkage)
Tensile/tear strength (for workwear-grade lines)
Chemical finish declarations where required
Labeling compliance (fiber content, care, country of origin)

Provide your region’s standards (e.g., industrial laundry specs); we align test plans accordingly.

9) Sampling, Lead Times & MOQ

Development Sample (Proto): 7–12 days after confirming fabric & trims.
Pre-Production Sample (PPS): 7–10 days after proto approval.
Bulk Production: usually 25–45 days, depending on fabric dyeing queue and order size.
MOQ (guideline, flexible by fabric):
- Solid color per style: 200–500 sets (or 300–800 pcs tops/pants).
- Mixed sizes allowed; color splits negotiable.
Reorders: faster cycles; we keep patterns, BOMs, and color standards on file.

10) Pricing Drivers

Fabric type & weight (4-way stretch and special finishes cost more)
Branding method (embroidery area, stitch count, number of positions)
Pocket complexity & trims (zippers, rib cuffs, reflective)
Color count & split (more colors = higher dye lot complexity)
Packaging level (retail vs. bulk)
We’ll quote EXW/FOB/CIF with breakdowns so you can optimize.

11) Packaging Options

Bulk: 1 polybag per garment; size/PO labels; 40–80 pcs per carton by size curve.
Retail-Ready: size sticker, hangtag, folding board, banderole, barcode/UPC/EAN.
Sustainability: recycled polybags, FSC hangtags, minimal-ink cartons on request.
Carton Spec: we share outer carton size, GW/NW, pallet plan to reduce freight.

12) Quality Assurance & AQL

Incoming: fabric inspection (shade bands, defects).
In-Line: stitching, seam strength, measurement checks.
Final: AQL 2.5/4.0 (or per your SOP); needle detection if required.
Traceability: PO-level records for fabric lot, trims, and inspection reports.

13) Sustainability & Ethical Options

Recycled polyester content where feasible.
OEKO-TEX® Standard 100-compliant materials (when specified).
Water-saving dye processes (availability by mill).
Ethical manufacturing declarations and social audits (on request).

14) What We Need to Quote Fast

Target fabric & performance (e.g., 4-way stretch + DWR).
Styles & pocket maps (reference images okay).
Branding method & placements.
Color list (Pantone or lab dips).
Size range & split.
Quantity per color/style and shipment terms (FOB/CIF).
Required timeline and destination.

Quick FAQs

Can you match our existing brand color?
Yes—Pantone matching with lab dips for approval.
Can you do small pilots?
We offer pilot MOQs for new programs and scale up with you.
Industrial laundry safe?
We select fabrics/threads/labels that withstand specified wash temps and cycles.