Cycling Jersey (Short-Sleeve, Race Fit)
Front zip, 3 rear cargo pockets, silicone gripper hem, full-sublimation panel construction.
Spec a jersey →
Cycling apparel · race kit · DTC brands & amateur teams
A Cycling Apparel Manufacturer That Engineers the Chamois, Not Just the Print
Italian-source pads built in a measured 3-density stack, full sublimation held to ΔE ≤1.5 within every batch, and a complete 6-SKU race kit out of one factory on one PO — the build details your last print-only supplier skipped.
- Italian-sourcechamois pads
- ΔE ≤1.5within-batch sublimation
- 6-SKU / 1 POfull multi-season kit
3-Density Cross-Section
Top sheetantibacterial · moisture-wicking face
80 kg/m³sit-bone seat zone · high density
60 kg/m³mid transition · flex + return
40 kg/m³perimeter taper · chafe-free edge
Molded center perineal relief channel
ΔE ≤1.5 color-lock — every panel of a team order reads as one colorway, batch to batch.
Product Range
Custom Cycling Jerseys, Bib Shorts, Long-Sleeve Thermal, Tights, Vests and Warmers We Cut and Sew
Six cycling SKUs that build one annual kit. Race-fit cut, full-sublimation construction.
Cycling Bib Shorts (Italian-Source Chamois)
Italian-source chamois, 3-density 80/60/40 kg/m³ zoning, 12-panel flatlock attachment.
Spec a bib short →
Long-Sleeve / Thermal Jersey
Brushed-back fleece, windproof front panel, optional merino-blend body.
Spec a long-sleeve →
Bib Tights / Winter Tights
Roubaix thermal fabric, windproof front, ankle zipper plus reflective tab, chamois integrated.
Spec a winter tight →
Cycling Vest / Wind Gilet
Windproof front and mesh back, packable into rear pocket, drop-tail cut for riding position.
View wind-shell construction →
Arm + Leg Warmers + Skull Cap (Add-Ons)
Thermal Roubaix arm and leg warmers plus skull cap, silicone gripper bands, team-kit add-on bundle.
View cycling socks →
Discipline × Apparel
Custom Cycling Apparel Spec'd to Your Discipline: Road, Gravel, MTB, Triathlon, Indoor, and Endurance Gran Fondo
Gravel grit. Road aero. MTB abrasion. Triathlon hydrodynamics. We spec the fabric to the discipline.
Road Racing
High-speed aero, group ride pelotons. Apparel built for race-cut hold and aero seam alignment.
SKU mix: Race-fit jersey · bib shorts · arm warmers
Fabric tier: 110 GSM aero-knit polyester · race-cut · low-pad chamois for short-effort
Gravel / Adventure
Endurance-bias, mixed surface, longer rides. Apparel takes more chamois density and a relaxed fit.
SKU mix: Relaxed-fit jersey · bib short (higher chamois density) · vest
Fabric tier: 140 GSM textured polyester · added side pocket · reflective accent at lower back
Mountain Biking (MTB / Enduro)
Trail abrasion, baggy fit over a chamois liner. Apparel built for repeated brush contact and ventilation.
SKU mix: Loose-fit jersey · technical baggy short (separate chamois liner) · arm warmers
Fabric tier: 160 GSM ripstop polyester · 30,000+ Martindale abrasion cycles · ventilation panels
Triathlon
Swim-to-bike-to-run hydrodynamic, fast transitions. Apparel runs thin and dries fast under load.
SKU mix: Tri suit (one-piece) · sleeveless jersey · minimal-pad chamois
Fabric tier: 90 GSM compression poly-elastane · quick-dry surface · sub-1cm-thickness chamois
Indoor Cycling (Zwift / Smart Trainer / Spin Class)
High-sweat sustained effort with no wind. Apparel maxes out ventilation and stays put on the trainer.
SKU mix: Ultra-light sleeveless jersey · minimal-pad bib · sweatband
Fabric tier: 90 GSM mesh polyester · sweat-wicking · grip-pattern bib hem stays put on trainer
Endurance / Gran Fondo / Charity Ride
4-8 hour rides, mixed weather, sponsor visibility, group identity. Full kit with sponsor logos on every piece.
SKU mix: Full 6-SKU kit with sponsor logos across every piece
Fabric tier: 140 GSM all-weather polyester · Ultra-Endurance 3-density chamois · reflective accents
Chamois Engineering
Italian-Source Chamois Engineering for Cycling Bib Shorts Manufacturing
The make-or-break component. We source the chamois grades Italian and Portuguese factories use.
| Chamois Spec | Berun Cycling Standard | Industry Commodity |
|---|---|---|
| Supplier source | Italian-source (Cytech / Elastic-Interface affiliated, Tier-1 European supplier) | Generic Asian commodity ($4-6 / pad) |
| Density zoning | 3-density gradient: 80 kg/m³ sit-bone / 60 kg/m³ perineum / 40 kg/m³ edge | Single-density ~50 kg/m³ throughout |
| Gender mold | Separate male / female / unisex molds, anatomically distinct | One-pad-fits-all unisex |
| Cover fabric | 80-denier suede-coated polyester, anti-bacterial, 30,000+ Martindale cycles | 40-denier commodity polyester |
| Attachment | 12-panel flatlock seam, full perimeter sewn-in to bib body | Perimeter glue + chain-stitch at 4 points |
| Endurance test | 6-hour continuous-ride simulation, zero pressure-point fail criterion | None (no in-house testing) |
| Sit-bone landing | Anatomical sit-bone pocket molded into pad | Flat foam, no landing pocket |
3 chamois series · pick by ride duration
Sprint chamois — ≤2 hr rides (crit racing, indoor cycling). Thinner, low-profile.
Endurance chamois — 2-5 hr rides (road racing, gravel). Standard 3-density.
Ultra-Endurance chamois — 5-12 hr rides (Gran Fondo, multi-day tours). Thicker sit-bone density + extended landing.
Chamois cross-section showing 3-density zones (80 / 60 / 40 kg/m³) with 80-denier suede-coated cover and 12-panel flatlock perimeter attachment.
Failure Modes → Fixes
Three Cycling Apparel Failure Modes We Engineer Out
Three things our new customers showed us after their last vendor burned them.
1 Chamois Bunching and Saddle Sores
Pain
Chamois bunched, cover ripped, three riders got saddle sores
Pelotonia 80-rider charity team. Chamois bunched at the inseam on the first training ride. One cover ripped at hour two. Three riders developed saddle sores by day one of the 200-mile event. Coordinator refunded $4,800.
Our fix
Italian chamois, 3-density 80/60/40, 12-panel flatlock, 6-hour test
Italian-source chamois (Cytech / Elastic-Interface affiliated). 3-density 80/60/40 kg/m³. Gender-specific molds. 12-panel flatlock seam — no glue, no perimeter-only stitching. 80-denier suede-coated cover. 6-hour endurance test on every pre-bulk sample.
2 Within-Batch Sublimation Color Drift
Pain
Twelve teammates ordered, three came back the wrong shade
Road racing club ordered 12 jerseys + 12 bibs in team navy with sponsor logos. Season-opener photo: 9 true navy, 2 grey-navy, 1 lavender. Sponsor logo drifted 2-3mm on 4 jerseys. Energy-drink sponsor cancelled the $1,200 contribution citing brand-standards failure.
Our fix
ΔE ≤ 1.5 within-batch, ±1mm registration, dedicated sublimation line
ΔE ≤ 1.5 within-batch — spectrophotometer-verified on every piece pre-shipment (distinct from cross-PO drift on knit-stretch sister pages). ±1mm registration tolerance on sponsor logos crossing panel seams. Dedicated sublimation line tuned for cycling polyester. UV-stable disperse-dye ink. Pre-bulk batch sample (1 jersey + 1 bib + 1 warmer) shipped for sign-off before bulk runs.
3 Four-Vendor Patchwork for One Team Kit
Pain
Four vendors, $8,500, six months, sixty percent unhappy
Amateur club organizer assembled the 2024 kit via 4 vendors: jerseys + bibs from one factory, vest + warmers from another, local screen-printer for sponsor logos (peeled after 4 washes), drop-ship winter tights (different navy, different stretch). Four navy shades in the group photo. $8,500 spent, six months sourcing, 60% of riders unhappy.
Our fix
One PM, one PO, 600 cross-SKU Team Pack, multi-season delivery
Single PM, single PO across all 6 SKUs. Same dye batch + same fabric mill for matching-color SKUs. Cycling Team Pack MOQ: 100 jerseys + 100 bibs + 100 long-sleeve + 100 tights + 100 vests + 100 warmer bundles = 600 cross-SKU one PO. Summer Q1, shoulder Q2, winter Q3 — same color story across all three deliveries.
Get a cycling kit spec match in 24 hours
Send your design brief or tech-pack. Name your discipline and kit composition. We confirm fabric, MOQ split, and lead time within one business day.
Four production paths
Cycling Apparel OEM, ODM, Private Label, and the Cycling Team Pack
Four production models for four commitment levels. The Cycling Team Pack is our cycling-only program.
OEM (Cut-and-Sew)
Your tech-pack, our cut-and-sew lines, full custom control.
- MOQ 100 baseline / SKU
- 35-42 day lead time
- 1-piece sample USD 45 (waived after first PO)
- AQL 2.5 pre-shipment
Best for: DTC cycling brands with finished tech-packs and a defined capsule launch plan.
View full OEM process →ODM (Cycling-Cut Block Patterns)
40+ cycling-cut block patterns. You customize color, sublimation art, sponsor logos.
- MOQ 100 / SKU
- 30-35 day lead time
- 1-piece sample USD 45
- Pattern royalty waived
Best for: New cycling brands without a tech-pack, or teams adapting an existing pattern.
View ODM block patterns →Private Label
Our cycling blanks (jerseys, bibs, vests), your hangtag, care label, sponsor placement.
- MOQ 100 / style
- 14-21 day lead time
- Existing blank library
- Fastest market entry
Best for: Founders racing to first PO or club captains testing a one-season trial kit fast.
View private label process →Cycling Team Pack
One factory, one PM, one PO across the full 6-SKU annual kit. Single dye batch, single sublimation pass, single QC sign-off across summer / shoulder / winter.
MOQ split (cross-SKU)100 jerseys + 100 bibs + 100 long-sleeve + 100 tights + 100 vests + 100 warmer bundles = 600 cross-SKU one PO
- Multi-season delivery: summer Q1 / shoulder Q2 / winter Q3
- Single PM + single account + single invoice
- Same dye batch for matching-color SKUs
- Cross-SKU sample pull (6 pieces) for color-match sign-off
- Sponsor-logo registration ±1mm verified per SKU
Best for: Amateur cycling clubs, charity-ride teams, Gran Fondo organizers, corporate / college cycling clubs. DTC brands launching a complete multi-SKU cycling capsule.
Build your cycling team kit →
Sourcing Process
Cycling Apparel Manufacturing Process: From Design Brief to Full Team Kit Shipment
Five steps. Two are cycling-specific. None are negotiable.
1. Design brief or tech-pack intake Day 1-2
Submit design brief, sketch, or tech-pack plus sponsor logo files (vector preferred: .ai, .eps, .svg) plus Pantone references. We confirm chamois availability, sublimation line capacity, fabric in stock, and quote per-SKU MOQ split. For team kits we ask about discipline, rider headcount, sponsor brand standards, and season opener date.
2. Chamois fit try-on Day 3-7 · CYCLING-SPECIFIC
Pre-bulk: 1 bib short sample produced with chamois in spec. Shipped to your captain or lead rider for an actual ride try-on (≥2 hr). Pass criterion: zero sit-bone pressure complaint, zero cover-fabric pilling, zero perimeter shift. Most factories skip rider try-on entirely.
Generic OEM at /services/oem does not have this step.
3. Lab dip + first sample + sublimation registration test Day 8-14
Pantone match to within-batch ΔE ≤ 1.5. 1 jersey + 1 bib + (if applicable) 1 warmer sample printed in production-line conditions. Sponsor-logo placement measured at ±1mm tolerance, especially on logos crossing panel seams. Sample shipped via DHL / FedEx (3-5 day transit). USD 45 sample fee waived after first PO.
4. Pre-bulk sublimation batch sample (cross-SKU color match) Day 15-21 · CYCLING-SPECIFIC
Before bulk runs: factory prints 1 of each SKU in the kit (up to 6 pieces for full Cycling Team Pack) in actual production print-run conditions, photographs them together under controlled studio lighting, and ships the multi-SKU sample pull to you for cross-SKU color-match and brand-standards sign-off. Catches the “navy on bib ≠ navy on jersey” failure before bulk.
5. Bulk cut-sew + AQL 2.5 pre-shipment + ship Day 22-60
Cut-and-sew across dedicated lines (sublimation + chamois integration + cut-sew) under one PM. Per-piece sublimation ΔE check at sublimation station. Pre-shipment AQL 2.5 inspection. Bureau Veritas / SGS third-party inspection on request. FOB your designated port.
End-to-end total: single SKU 50-60 days. Multi-season Cycling Team Pack: 90-120 days summer-to-winter delivery window — same factory, same color story, same QC across all seasons.
FAQ
Cycling Apparel Manufacturer FAQ
Eight questions cycling buyers ask before sending a tech-pack or team brief. Four for DTC brands, four for amateur teams.
Group A — For DTC cycling brands
What’s the MOQ for a single cycling SKU like a flagship jersey or bib short?
100 pieces per SKU baseline (split across XS-XXL from that 100, not multiplied per size). 100/SKU on ODM block patterns. 100/style on Private Label. For a full multi-SKU capsule, ask about the Cycling Team Pack rule — 600 pieces cross-SKU one PO.
Can I order 1 sample to test before committing to a 100-piece bulk?
Yes. 1-piece sample, USD 45 fee, 5 working days when fabric is in stock. Sample fee waived after first bulk PO. You can sample any of the 6 cycling SKUs before deciding (jersey, bib, long-sleeve, tight, vest, warmers).
How do I verify the chamois is actually Italian-source and not generic Asian foam relabeled?
We disclose the chamois supplier name on request (Cytech-affiliated or Elastic-Interface-affiliated Tier-1 European supplier). We also ship a chamois cross-section cutaway sample (one bib cut open) so you can verify the 3-density zoning and 12-panel flatlock attachment yourself before committing.
My capsule depends on a color story across 6 SKUs. How do you prevent cross-SKU drift?
Same dye batch + same fabric mill across matching-color SKUs. Before bulk we produce 1 of each SKU in production print-run conditions, photograph them together under controlled studio lighting, and ship the 6-piece pull for sign-off. ΔE ≤ 1.5 within-batch tolerance, spectrophotometer-verified on every piece.
Group B — For amateur teams and clubs
I don’t have a tech-pack — I have a team design brief, sponsor logo files, and a rider headcount. Can you still produce my team kit?
Yes. ODM is the entry path: 40+ cycling-cut block patterns (race-fit jersey, gravel-fit jersey, bib short with Italian-source chamois, bib tight, vest, warmers). You provide color, sublimation art, sponsor logos, rider sizes. We cut-sew and sublimate against the block pattern. No formal tech-pack required.
How does the Cycling Team Pack work — what’s the actual MOQ split?
Cycling Team Pack is our cycling-only program for full team kits. MOQ split: 100 jerseys + 100 bibs + 100 long-sleeve + 100 tights + 100 vests + 100 warmer bundles = 600 cross-SKU one PO (vs 100 baseline single-SKU). One PM, one PO number, one invoice, same dye batch across matching-color SKUs. Multi-season delivery: summer Q1, shoulder Q2, winter Q3 — all under one master spec.
My team has sponsor logos with brand-standards tolerance. What’s your registration accuracy?
±1mm tolerance on sponsor-logo placement, verified per piece pre-shipment. Before bulk we measure registration on the 6-piece cross-SKU sample pull and confirm sign-off against your sponsor’s brand-standards file (if you can share it). Sponsor cancellations from logo drift are a specific failure mode we engineer out.
Our season opens in 3 months. Can you deliver a full team kit in time?
Yes, with planning. Cycling Team Pack lead time from brief intake → chamois try-on → lab dip → sublimation batch sample → bulk ≈ 70-90 days for the summer kit (jersey + bib + warmers). Long-sleeve + vest add 30 days. Winter tights add another 30 days. For a 3-month window: prioritize summer kit, ship shoulder + winter under the same Cycling Team Pack PO.
Trust & Compliance
Certified Cycling Apparel Factory: OEKO-TEX, BSCI, WRAP, GRS, and Higg
Five certifications. Each matters for a cycling-specific reason. Twelve brands and clubs ship with us today.
OEKO-TEX Standard 100
23.HCN.74521
Skin-contact safety for chamois cover in direct-saddle contact, 4-8 hours per ride.
Request PDF
BSCI
BSCI-CN-2024-08-15
Social compliance for cycling brand procurement and sponsorship audit-readiness.
Request PDF
GRS
CU 1014387 GRS-2024
Recycled-polyester chain-of-custody for eco cycling capsules (rPET jerseys, bibs).
Request PDF
Higg FEM
HIG-FEM-2024-CN-08 · 82/100
Dye-house traceability for within-batch sublimation color consistency.
Request PDF“
We tried four vendors in 2024 — jerseys from one, vest and warmers from another, sponsor logos heat-pressed locally, winter tights drop-shipped. $8,500, six months, and the navy didn’t match across pieces. For 2025 Berun ran the full kit through one Cycling Team Pack PO. Same dye batch across all six SKUs. The sponsor signed for another season.
12 active partners across cycling clubs, DTC cycling brands, athleisure, yoga, training, and outdoor
Akarra Active
Aspen Athletic Co.
Berlin Mile Club
Capella Sport
Coastline Performance
Forge Lab Athletics
Granite Run
Kindred Strength
Meridian Move
Northcrest Outdoor
Sequoia Sweat
Verdant Athletics