Full-Coverage Underwire Support Bra | B2B OEM/ODM Manufacturer Specifications

Engineered for stability and all-day structural support, this Full-Coverage Underwire Support Bra addresses the common performance failure points of commercial innerwear: underwire deformation, strap tension fatigue, and cup gaping. Built with a high-containment cup architecture and calibrated underwire suspension, it transfers weight evenly across the torso. Available for private label, white label, and custom technical specification manufacturing.

Key Features

Calibrated Underwire Suspension: Enclosed in multi-layer plush channel lining to prevent wire poke-through, distortion, or metal fatigue under tension.

Full-Coverage Containment Architecture: Deep-cup structural shaping prevents spillage, secures high-volume busts, and maintains a stable silhouette.

Ergonomic Wide Anchor Band: Reinforced bottom elastic band distributes upward lift, preventing roll-up and band displacement during movement.

Reinforced Stress-Point Bartacking: High-tension zones-including strap attachment points, wing seams, and hook-and-eye closures-utilize high-density bartack stitching to prevent seam failure.

Moisture-Wicking Inner Lining: Brushed micro-fiber or cotton-blend interior minimizes friction and manages thermal load during extended wear.

Technical Specifications

Parameter	Specification Standard	Tolerance / Notes
Size Range	32B to 44DDD (US/UK sizing matrix)	Custom grading available per tech pack
Underwire Gauge	Memory carbon steel wire (0.8mm – 1.2mm width)	Corrosion-resistant nylon coating
Stitch Density (SPI)	12 to 14 stitches per inch	Main structural seams
Elastic Recovery	≥ 95% recovery rate after 100% elongation	Tested to ASTM D4964
Color Fastness	Grade 4 to 5 (Wet and Dry crocking)	Tested to AATCC 8 / ISO 105-X12
MOQ per Style/Color	1,000 pieces per colorway	Graded across requested sizes

Materials & Construction

Outer Fabric	Nylon-Spandex Warp Knit (High tensile strength, matte finish)
Inner Channel	Multi-Layer Needle-Punch Non-Woven + Plush Elastic Tape
Underwire	Carbon Steel Core with Dip-Molded Nylon Tip Insulation
Hardware	Zinc Alloy Rings and Sliders (Nickel-Free, Lead-Free)
Fabric Composition	Standard configuration is 82% Nylon / 18% Elastane (220 GSM) for body panels; 85% Polyester / 15% Spandex for wing stability. Alternative organic cotton or bamboo blends available on request.
Construction Build	3-piece or 4-piece cut-and-sew cup construction provides directional support vectoring, avoiding the structural collapse typical of molded foam cups in larger sizes.
Finishing	Flat-lock and clean-finish edge binding eliminate skin chaffing along the neckline and underarm wings.

Sizes & Customization

Precision Grading & Regional Matrices: Standard production accommodates US, UK, and EU sizing matrices. To address strict regional fit variations, we support custom cup-depth ratios, side-wing height modifications, and specialized grading rules to match your brand's specific fit block.

Customization Options:

Digital Tech Pack Integration: Full acceptance of digital specifications via DXF, Gerber (ACCU), or Lectra pattern formats.
Branding: Custom woven labels, heat-transfer care labels, branded hook-and-eye pull tabs, and custom-embossed hardware.
Structural Adjustments: Wire gauge modification, cushion pad insertion, strap width scaling (15mm to 22mm), and hook-and-eye row expansion (from 2-hook to 4-hook configurations).
Fabric Substitutions: Recycled nylon (GRS certified), modal linings, or specialized antimicrobial treatments.

Applications

01/

Plus-Size Intimate Apparel Collections: Structural foundationwear requiring rigorous bust control and weight distribution.

02/

Everyday Comfort Line Extensions: High-support daily wear designed for consumers requiring long-duration postural relief.

03/

Medical & Post-Surgical Support Lines: Modified configurations featuring soft-compression side wings and pressure-relieving wider straps.

04/

Department Store Private Label Programs: High-volume retail supply meeting stringent global quality tier requirements.

Quality Control & Manufacturing Capabilities

Our in-house production facility integrates automated fabric spreading, CNC laser cutting, and computerized multi-needle sewing lines to maintain dimensional stability across large production batches.

Needle Detection & Inspection: 100% of finished garments pass through automated conveyor metal/needle detectors before packaging.

Dimensional Stability Testing: Fabric lots undergo shrinkage, bursting strength (ASTM D3786), and seam slippage tests prior to cutting. (Full laboratory test report PDFs available upon request during audit).

In-Line & Final AQL: Strict adherence to ISO 2859-1 (AQL 2.5 standard for critical defects; AQL 4.0 for major/minor defects) executed by certified quality inspectors at four production stages.

Compliance: Facilities operate under BSCI social compliance standards, and material inputs meet OEKO-TEX Standard 100 Class II requirements for direct skin contact.

Packaging & Private Label OEM/ODM

Packaging Standards: Individual polybag packing with moisture-absorbing silica gel pack. Flat-packed or folded to minimize volumetric shipping costs. Master cartons use heavy-duty 5-layer corrugated cardboard with waterproof inner lining.

Barcode & Labeling: Customized UPC/EAN barcode stickers, carton marks, and hanging tags applied per client retail distribution requirements.

OEM/ODM Workflow:

Tech Pack Review & Material Sourcing (3–5 days)
Counter Sample Development & Fit Testing (7–10 days)
Pre-Production Sample (PPS) Approval
Mass Production & AQL Inspection (25–35 days depending on volume)

Frequently Asked Questions

Q: What is the standard sample lead time and sample cost policy?

A: Standard development samples take 7 to 10 days upon tech pack and material confirmation. Sample fees are refunded upon the placement of a bulk order meeting the minimum order quantity (MOQ).

Q: How do you prevent underwire poke-through during prolonged wear?

A: We use a 3-layer channel construction combining high-density needle-punched non-woven fabric, plush warp-knitted tape, and a double-lock stitch density of 14 SPI. Furthermore, all wire ends are sealed with dip-molded nylon insulation tips to eliminate sharp friction points.

Q: Can we substitute the standard nylon-spandex fabric with GRS-certified recycled materials?

A: Yes. We maintain an audited supply chain of Global Recycled Standard (GRS) certified nylon and eco-friendly modal yarns, complete with Transaction Certificates (TC) for shipment.

Q: What is your standard production lead time for repeat bulk orders?

A: Standard repeat production runs require 25 to 30 days following pre-production sample approval and receipt of the deposit. Peak season schedules may vary.

Q: Are your materials tested for harmful substances and skin irritation?

A: All raw materials-including fabrics, elastics, threads, and dyes-comply with OEKO-TEX Standard 100 regulations, ensuring absence of restricted azo dyes, formaldehyde, and heavy metals.

Q: What file formats do you accept for custom tech packs and grading rules?

A: We accept digital tech packs in PDF format alongside pattern grading files in DXF, Gerber (ACCU), or Lectra formats to ensure precise size replication across all regional fit specifications.

Request a Quote

To receive a detailed quotation including FOB/CIF pricing, lead times, and shipping estimates, please provide the following parameters via our inquiry form or direct email:

1.Target order quantity (MOQ starts at 1,000 pcs/color)
2.Size breakdown and colorway count

3.Tech pack or reference sample specification
4.Target delivery port / Incoterms preference

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