From Concept to Creation: A Guide to Successful Product Development for Outdoor Apparel and Soft Goods, Part 1 of 3

Do you have a brilliant idea for an outdoor product and dream of seeing it come to life? Turning a concept into a product involves a well-thought-out process that encompasses everything from understanding your competitors, to pricing, to getting referrals to trusted manufacturers.?

In this 3-part series, we'll walk you through the essential steps of product development, show you how to create a tech pack to communicate your product specifications to factories, and share tips for finding the right production partner. So, roll up your sleeves and get ready to embark on the product development path – your dream product awaits!

This three-part blog series is a summary of the Idea to Production Workshop led by Karen Buscemi of Detroit Sewn and Lionel Vargas Cruz of ISAIC (Industrial Sewing and Innovation Center). More on them below.

Part 1: The Steps of the Product Development Process for Domestic Manufacturers

1. Conceptualizing Your Product: Start with the basics! To begin the journey of product development, it’s important to have clarity on what you want to create and why. Make sure you’ve done some groundwork and market research and have a deep understanding of the following:

• What is your product idea??
• What makes it unique compared to existing products in the market (your competitive differentiation)?
• Who is your target audience? What are your customer personas?
• And why would they want to buy your product? In other words, what’s your value proposition?

2. Communicating Your Vision: Communicating your product idea effectively to a manufacturer is essential for successful collaboration. There are many methods you can use to prepare for those conversations. These include sketching your concept by hand or using software like Adobe Illustrator. You can also create a Pinterest board with inspiration images highlighting specific elements you like from various products you want to incorporate into your design in the description. Or try writing out a description of your product’s style and fit.

3. Figure out Pricing: Before you talk to your production partner, it’s important to determine the price range at which you plan to sell your product. To set an appropriate price, do pricing interviews with your target customer to better understand their budget and research the prices of similar products on the market. In addition, you’ll want to consider the materials you'll use, which will impact the product's quality and cost. Ensure that the materials align with your target audience's preferences and match the overall design and functionality of the product. Evaluate factors such as fabric composition, durability, texture, and performance attributes when choosing your materials.?

4. Meeting with Manufacturers: During the initial consultation, you'll learn more about the manufacturer's capabilities, processes, and timelines. The manufacturer will seek to understand your requirements, answer any questions, and provide an estimated invoice for the production.?

5. Pattern Making and Sourcing Materials: During this step, you will work with a design agency, consultant, or your manufacturer to develop both paper and digital patterns (templates used to cut out the fabric according to your product specifications). These patterns serve as the starting point for the tech pack (a robust document that serves as a blueprint for your product) and guide the sample-making process. Simultaneously, you (or the manufacturer) need to source the necessary materials, including fabrics, hardware, and trims, while considering factors like quality, availability, and cost. You can choose to source the materials yourself which might be cheaper but more time consuming. Or you can have your manufacturer source the materials as they may have relationships with fabric mills and other suppliers that allow them to negotiate better pricing, but they will need to integrate the cost of their work into your product. Pattern making and sourcing materials can be done simultaneously and can take as short as 2 weeks.?

6. Prototyping and Sample Revisions: In this step, you’ll create a one-off physical sample of your product to evaluate its fit, design, and functionality. It’s important to test your sample in different conditions to ensure that it meets the quality and durability standards you plan to promise to your customers. Be prepared for multiple revisions as you refine the prototype to achieve your desired outcome. Budget for the additional time and costs involved in the revision process. Each sample or revision can take 2 weeks.?

7. Pattern Grading: If you’re creating a different-sized product i.e. apparel, you will need to work with your designer or manufacturer to take the final pattern from your prototype and adjust it to create different sizes called grading. The grading process is critical for maintaining the integrity of the design across all sizes, and you may want your manufacturer to do a size run of your graded patterns to test for fit. This step can take over 2 weeks depending on how many revisions are needed.?

8. Production: Production is the process of converting fabric into large quantities of finished products including cutting, sewing, and finishing. Make sure you are budgeting for the extra time it may take to get on the factory’s production schedule, in addition to the 6-12 weeks it typically takes to manufacture a textile based product.?

9. Quality Control & Packaging: Decide whether the packaging of your product will be handled by the manufacturer or yourself. Design packaging that aligns with your brand identity and protects the product during transit. Budget 1 week for quality control and packaging if done with the factory.?

In part 2 of this 3 part series, we will talk about the steps in creating a comprehensive tech pack.

About?

Detroit Sewn is a full-service cut and sew manufacturer located in Southeast Michigan, focusing on apparel, accessories and home goods. We offer low minimums, timely turnaround, thorough communication and high-quality results. Services include product development, materials sourcing, pattern making, sample making, pattern grading, tech packs, decorating services including embroidery, heat transfers, screen printing and sublimation, and small-to-large production runs for cutting and sewing. Online learning and one-on-one coaching for brands is also available. Contact: Karen Buscemi, [email protected].

Industrial Sewing and Innovation Center (ISAIC) is a national nonprofit institute for soft goods manufacturing that works toward sustainable and profitable domestic manufacturing located in Detroit, Michigan. In the process, their goal is to redefine the future of work by putting people trained in advanced and emerging manufacturing technologies at the forefront of sustainable soft goods production with a commitment to the wellbeing of our team, partners, community, and planet.?

Michigan Economic Development Corporation (MEDC) and the Office of Outdoor Recreation:

Pure Michigan Business Connect (PMBC) is a unit of the MEDC that delivers a suite of services to help diversify and strengthen your supply chain. PMBC can connect your business to local, national, and global purchasers through customized procurement or joint venture matchmaking searches, summits and buyer tours.

Michigan Outdoor Recreation Industry Office is charged with supporting and growing Michigan’s outdoor recreation economy. The Office is a joint project of the MEDC and the Department of Natural Resources that works alongside outdoor recreation businesses and organizations to create innovative products, attract, retain and develop outdoor industry jobs and improve outdoor accessibility for all.??