Custom manufacturing
Flannel Shirt Manufacturer — Brushed Yarn-Dyed Check
Flannel is a construction, not a print. The check is dyed into the yarn before weaving, so it runs through the fabric rather than sitting on the surface, and the weave is then brushed to raise a soft nap. That combination is why a real flannel feels soft and looks deep, and why a printed imitation cannot match it. The detail that separates a well-made flannel from a careless one is the pocket: a check that runs straight through the pocket, aligned to the body, is the mark of a garment that was cut with care.
500 pcsMinimum order
7–10 daysSampling
180,000 pcs / monthMonthly capacity
Fabric weight and construction options
| Weight / type | Material | Best suited to |
|---|---|---|
| 100–120 gsm | Single-brushed cotton flannel | Lightweight, layering and transitional |
| 120–150 gsm | Double-brushed flannel | Softer nap, the standard flannel hand-feel |
| 150–170 gsm | Heavyweight flannel | Structured, worn as a light outer layer |
| Cotton–poly blend | Brushed yarn-dyed | Less shrinkage, lower cost, holds nap longer |
Available decoration methods
| Method | Specification | Typical use |
|---|---|---|
| Embroidery | Chest or back yoke | Over a check, keep the stitch count modest so the logo reads |
| Woven label | Chest pocket or side seam | A heritage-label look that suits the fabric |
| Leather / suede patch | Chest | Premium trim common on outdoor-positioned flannel |
| Screen printing | 1–4 colours | Possible, but a check fights with any added print; usually placement only |
| Contrast lining | Collar and cuff inner | A quiet premium detail visible when worn open |
Specifications we manufacture to
- Fabric
- Yarn-dyed cotton flannel, single or double brushed
- Weight range
- 100 – 170 gsm
- Check
- Yarn-dyed check, woven not printed; pattern scale specified
- Chest pocket cut to align with the body check
- Collar
- Point, button-down, spread; fused or unfused
- Placket
- Full button, specified button type
- MOQ
- 500 pcs per colourway
- Sampling
- 7–10 days
Decoration methods for this product
Related product categories
Frequently asked questions
What is the difference between yarn-dyed and printed checks?
In a yarn-dyed check the pattern is dyed into the yarn, so it is visible on both faces and in the fold, and it does not fade off the surface. In a printed check the pattern sits on the fabric, fades with wear and shows a white edge where it is cut. Real flannel is yarn-dyed, and the price difference is real because the fabric is more expensive to make.
Why does the check alignment on the pocket matter?
Because it is the most visible sign of how carefully the shirt was cut. A flannel cut in bulk has to have each panel matched so the check lines up at the side seams, and the pocket must continue the body pattern. If it does not, the garment reads as cheap regardless of the fabric. We set the pocket line-up in the tech pack so the factory cuts it correctly every time.
Does flannel shrink more than other woven fabric?
Brushed cotton can shrink noticeably if it is not pre-shrunk. A flannel shirt that has not been pre-shrunk can move a full size on the first wash, which is fatal for a retailer. We specify a sanforised or pre-shrunk finish and wash-test it. It is not negotiable for a garment with a sold size chart.
Is flannel warm enough to wear as an outer layer?
At 150 gsm and up with a brushed finish, yes — it is commonly sold as a light outer shirt over a tee. At 100–120 gsm it is a layering piece under something heavier. Tell us the intended wear position and we will recommend the weight rather than just quoting what you asked for.