Our Process

Every Sail Stitch garment is crafted through a structured process that combines traditional techniques, modern quality control, and historically accurate materials.

At Sail Stitch, every garment is produced through a carefully managed process designed to ensure quality, consistency, and historical authenticity.

From the moment an order is received to the final packaging and shipment, each step is monitored by our production and quality control teams. Our goal is simple: deliver garments that meet the expectations of performers, reenactors, vendors, and historical enthusiasts.

1.) Order Confirmation & Proforma Invoice

The process begins once we receive an order from a partner or Fair vendor.

A person sitting at a desk using a laptop computer
A person sitting at a desk using a laptop computer
Proforma Invoice

Once confirmed, we generate a Proforma Invoice outlining the order specifications, pricing, and production schedule.

Order review

Our team reviews the order details including:

  • garment style and design

  • size breakdown (US/EU sizing)

  • fabric and colour requirements

  • accessories and trims requirement

  • desired delivery timeline

Once both parties agree upon payment terms, delivery timeline and specifications. We request the advance payment to commence the production.

Advance payment

2.) Fabric & Accessories Procurement

After order confirmation, the sourcing process begins. We procure fabric from our inhouse fabric shop or our trusted material suppliers.

We procure
  • historically appropriate fabrics

  • trims and decorative elements

  • metal, bone, wood or horn buttons

  • cords, laces, and ties

  • specialty accessories required for the garment design

Wherever possible we prioritize natural breathable fabrics and historically accurate materials to maintain authenticity.

3.) Fabric Dyeing & Conditioning

Before garment production begins, fabrics are carefully prepared to ensure consistent colour and performance.

This stage may include:
  • fabric scouring to remove mill oils and impurities

  • dyeing in controlled dye baths to achieve historically inspired tones

  • colour fixing to improve dye durability

  • washing and conditioning to soften the fabric

  • shrinkage stabilization before cutting

These steps ensure even colour, proper fabric behaviour during cutting and stitching, and consistency across production batches.

4.) Pre-Production Quality Control

Before production begins, the materials are inspected by our quality control team.

  • color consistency across fabric rolls

  • fabric strength and weave quality

  • dye stability

  • accessory quality and durability

  • measurement accuracy of trims and components

  • Size and patterns of buttons

Only materials that pass inspection proceed to production.

Checks include:

5.) Workshop Production Process

Once approved, materials are sent to the workshop where garment production begins.

The workshop process typically includes several stages.

Pattern Cutting

Each garment is cut according to pre-approved patterns based on US/EU sizing standards.

Patterns are carefully laid out on the fabric to ensure:

  • accurate sizing

  • efficient fabric usage

  • symmetry of design elements

Precise cutting is critical to ensure consistent garment shape and fit.

Stitching & Assembly

Once the pieces are cut, they move to the stitching stations where skilled tailors assemble the garment.

This includes:

  • joining major garment panels

  • reinforcing seams

  • attaching sleeves and collars

  • adding closures such as laces or buttons

For many historical garments, seam placement and construction techniques are chosen to replicate traditional styles while maintaining durability.

Accessories & Finishing Details

In the final assembly stage, decorative and functional elements are added.

These may include:

  • metal or horn buttons

  • lace-up eyelets

  • leather cords or ties

  • trims or decorative panels

These details bring the garment closer to its historical inspiration.

In-Production Quality Control

Quality checks are performed continuously during production.

This ensures:

  • stitching consistency

  • correct sizing

  • secure attachment of accessories

  • accurate garment construction

Any issues are corrected immediately to maintain production standards.

person in blue and white shirt
person in blue and white shirt

Once garments are completed, a final quality inspection is conducted.

  • correct measurements

  • clean stitching

  • fabric defects

  • loose threads

  • stains and chalk marks

  • loose buttons and accessories

  • accessory placement

  • overall finish and presentation

    Only garments that meet our standards proceed to packaging otherwise goes for rectification or rejection.

Each garment is checked for:

6.) Post-Production Quality Inspection

After final approval, garments are carefully packed for shipment.

white cardboard box on brown wooden table
white cardboard box on brown wooden table
  • products may be prepared for international export, or

  • made available for warehouse pickup

We work with trusted logistics partners to ensure timely and secure delivery to our clients for no extra charges.

Client may chose to pay the logistics partner directly.

Depending on the order arrangement:

7.) Packing, Final payment & Export Logistics

Once the shipment is received, we provide a feedback form to ensure our partnership remains successful.

white cardboard box on brown wooden table
white cardboard box on brown wooden table
  • Overall Satisfaction: Your experience with the ordering and delivery process.

  • Future Planning: Any suggestions or custom requirements for upcoming orders.

  • Quality Assurance: Identification of any manufacturing defects in the received shipment.

  • Resolution Strategy: Precise actions needed to rectify any issues immediately.

  • Resolutions: We offer hassle-free replacements for defective items. For minor corrections, we can include replacements in your next order to save on shipping costs.

We Address:

8.) FEEDBACK & COMPLAIN RESOLUTION