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Behind the Threads: Unravelling the Manufacturing Process of Football Shirts

In the pulsating world of football, where every match is a unique spectacle and every goal leaves an indelible mark, football shirts serve as emblems of pride, loyalty, and admiration. They connect fans with their favourite clubs, remind us of historic wins, and sometimes, even heartbreaking losses. But have you ever wondered about the fascinating journey a football shirt undertakes before it ends up in your hands, draped over your shoulders, or part of your esteemed collection?

In this riveting and informative blog series, we pull back the curtains to reveal the intricate manufacturing process of football shirts. We take you on an enlightening journey, from the initial concept and design stage, diving deep into the fabric and technological advancements that enhance player performance to the assembly line’s precision and skill, and finally, the stringent quality checks before a shirt is deemed fit for your wardrobe.

Each football shirt you own or intend to collect is a product of meticulous planning, cutting-edge technology, skilled craftsmanship, and rigorous testing. Understanding the hard work, creativity, and dedication involved in the creation process will surely enhance your appreciation for every thread and stitch, every panel and print of your beloved football shirts.

Join us in this immersive excursion, ‘Behind the Threads.’ Whether you’re an avid football shirt collector, an ardent football fan, or simply intrigued by the production process, this series will deepen your understanding and admiration for the football shirts you proudly wear or collect. 

Relish the manufacturing marvels of football shirts, from conceptualisation to final product, as we unravel the making of these symbols of team spirit, nostalgia, and football passion.

1. Concept to Design: The Story Behind Football Shirt Designing

The design of a football shirt goes beyond aesthetics; it is an embodiment of a club’s history, culture, and identity. The process begins with the club liaising with the kit manufacturer, outlining the desired themes, colours, and specific design elements to be incorporated. Designers then use these inputs to create a series of draft concepts and sketches, often working through multiple revisions and feedback cycles to ensure the final design meets the club’s vision.

Historically, football shirt designs were driven by club traditions and colours, but today, the commercial aspect of the sport cannot be ignored. Collaboration with sponsors also plays a crucial role in the design process. Balancing sponsor visibility and requirements with the club’s aesthetics and traditions can be challenging, but it is an integral part of modern football shirt design.

2. Material Matters: The Fabric and Technology Behind Football Shirts

The choice of fabric is pivotal in determining the comfort and functionality of a football shirt. The early days of football saw heavy cotton and wool jerseys, which were not ideal for on-pitch performance. With the advent of technological advancements, lightweight polyester emerged as the fabric of choice due to its functional advantages, durability, and ease of maintenance.

Manufacturers now use advanced fabric technologies, such as moisture-wicking and breathable materials that keep players dry, cool and comfortable on the pitch. These high-performance fabrics also glide smoothly on the skin, reducing chafing and irritation, thus allowing players to focus solely on their game.

Additionally, many football shirts feature strategically placed mesh panels, which enhance ventilation and airflow. Today’s manufacturing technology also allows for seamless construction, which eliminates chafing points and creates a more streamlined fit. Some football shirts also employ environmentally sustainable materials or processes, further enriching the story of each shirt.

3. Cutting and Stitching: The Assembly Line of Football Shirt Production

The mass production process begins once the design is finalised and the material chosen. The shirt design is split into individual components, such as the front panel, back panel, sleeves, and collar, which are subsequently printed on the fabric using techniques like screen printing or sublimation that ensure long-lasting and vibrant prints.

The fabric panels are then machine cut to create the individual pieces, which will be assembled to complete the shirt. The latest cutting technology maximises fabric utilisation and minimises material wastage, contributing to a more sustainable and environmentally-conscious manufacturing process.

Precision and skill play a key role in the assembly stage, where sewing machines and skilled workers come together to stitch the cut fabric pieces into a coherent football shirt. This stage demands impeccable attention to detail, carefully considering every seam and stitch. Quality controls are in place at every step to ensure consistent and impeccable craftsmanship.

4. Quality Control and Packaging: The Final Steps before the Shirt hits your Wardrobe

After the assembly stage, the football shirts undergo a battery of rigorous quality control checks. Each shirt is carefully examined for irregularities, errors, and defects in the stitching, fabric, printing or overall workmanship. Any shirt that doesn’t meet the high-quality standards is discarded or reworked to meet the guidelines set forth by the manufacturer and the club.

Lastly, the shirts are meticulously folded and packaged, often accompanied by tags featuring vital information such as size, care instructions, and barcodes for retail purposes. The packaging is designed to preserve the integrity and quality of the shirt, ensuring it reaches the consumer in pristine condition.

Conclusion:

As we unravelled the manufacturing process of football shirts, it becomes evident that the journey from conceptual sketches to a finished product requires tremendous planning, craftsmanship, and attention to detail. The amalgamation of art, engineering, and technology results in the football shirts we wear or collect, solidifying our connection to the beautiful game.

A deeper understanding of this process not only elevates our appreciation for the craftsmanship, materials, and design of football shirts but also inspires us to treasure the stories and passion they signify. The next time you don a football shirt or add one to your collection, take a moment to acknowledge the intricate journey each shirt has traversed, emblematic of the fervour and fervour of the beautiful game.

Ready to infuse the essence of your favourite clubs and national teams into your wardrobe or collection? At Matchday Mystery, we bring you the excitement of the unknown by offering handpicked, invigorating mystery football shirts that hold captivating stories and offer unparalleled creative designs. 

Embark on a thrilling journey where every football shirt you receive adds depth and character to your collection. Visit our website today to dive into the diverse world of football shirt designs and mystery box football shirts, steeped in rich history and enthralling tales of triumphs and tribulations on the pitch.

Discover more

Matchday Mystery

Ready to take your love of football to the next level and add an element of surprise to your collection? Then try out a mystery football shirt or an NBA Jersey and let the adventure begin!

With the thrill of not knowing which shirt you’ll receive, opening a mystery shirt or merch box is like unwrapping a surprise gift that’s just for you. So, whether you’re a collector or a fan, a mystery shirt / jersey is a fascinating choice that adds an element of adventure and surprise to your love of the game – whether that’s football or basketball!

Football Fans:

We’ve got mystery boxes for all – adults in sizes up to 5XL, womens, kids and for those looking to rekindle their love for the game, classic retro shirts from before 2016! Whether you’re a die-hard collector or a casual fan, the Mystery Retro Football Shirt is a must-have item. It’s a unique piece of football history that will make a great addition to your collection, or a perfect gift for the football enthusiast in your life.

Basketball Fans:

Elevate your NBA memorabilia collection with the Matchday Mystery NBA Jersey Box. Unbox the excitement, explore the history, and embrace the allure of these authentic and cherished pieces of NBA heritage.

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KIDS SIZES

Numerical Size 92 98 104 110 116 122 128
Age (yrs) 1-2 2-3 3-4 4-5 5-6 6-7 7-8
Chest (inch) 20-
20.5
21-
21.5
21.5-
22
22-
23
23-
24
24-
25
25-
25.5
Chest (cm) 50.8-
52.1
53.3-
54.6
54.6-
55.9
55.9-
58.4
58.4-
61
61-
63.5
63.5-
64.8
Waist (inch) 19.6-
20
20-
20.5
21-
21.5
21.5 22 22.5 22.5-
23
Waist (cm) 49.8-
50.8
50.8-
52.1
53.3-
54.6
54-
55
55-
56
57-
58
58-
58.4
Inseam (inch) 15 16 18 19.5 20.5 22 23.5
Inseam (cm) 38-
39
40-
41
45-
46
49-
50
52-
53
55-
56
58-
59

ADULT SIZES

UK Size XS S M L XL XXL 3XL
Chest (inch) 31-33 34-37 37-40 40-44 44-48 48-52 53-58
Chest (cm) 78-84 86-94 94-102 102-112 112-122 122-132 134-148
Width (inch) 17-18 18-19 19-20 21-22 23-24 24-25 25-27
Width (cm) 43-46 45-49 49-51 53-56 58-61 61-64 64-69
Length (inch) 24-25 25-26 27-28 28-29 30-31 32-33 33-34
Length (cm) 61-64 64-66 68-71 71-74 76-79 81-84 83-87

WOMENS SIZES

UK Size XXS XS S M L XL XXL
Numerical Size 0-2 4-6 8-10 12-14 16-18 20-22 24-26
Bust (inch) 28.7-
29.9
30-
32
33-
35
36-
37
38-
40
41-
43
44-
46
Bust (cm) 72.9-
76
76-
81.3
83.8-
88.9
91.4-
94
96.5-
101.6
104.1-
109.2
111.8-
116.8
Waist (inch) 22.4-
23.6
24-26 27-28 29-31 32-34 35-37 38-41
Waist (cm) 56.9-
59.9
61-66 68.6-
71.1
73.7-
78.7
81.3-
86.4
88.9-
94
96.5-
104.1
Hip  (inch) 32.3-
33.5
34-36 37-38 39-41 42-43 44-46 47-49
Hip  (cm) 82-
85.1
86.4-
91.4
94-
96.5
99.1-
104.1
106.7-
109.2
111.8-
116.8
119.4-
124.5