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
Cycling Apparel Manufacturer — Italian-Source 3-Density Chamois, 12-Panel Bib Construction, MOQ 100/SKU
Send your design brief or your existing cycling kit. We benchmark chamois fit on a rider try-on (≥2 hr), match Pantone within batch per-piece, and ship a 6-piece cross-SKU sample pull for color-match sign-off — that sign-off is the gate that opens the cutting table for bulk.
- Send your kitpad benchmarked on rider try-on
- One POjersey, bib, vest, warmers together
- You sign offchamois + print before bulk
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
Within-batch color-lock — every panel of a team order is printed against one Pantone reference and spectrophotometer-verified within batch.
Product Range
Jerseys, Bibs, Thermals, Tights, Vests, Warmers: One Cycling Wardrobe, One Factory
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
Six Cycling Disciplines and the Spec Differences We Build For: Road, Gravel, MTB, Triathlon, Indoor, Gran Fondo
Gravel grit. Road aero. MTB abrasion. Triathlon hydrodynamics. Each row below carries its own SKU mix, fabric tier, and chamois pad selection.
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 pad is the single spec a rider notices first. Our chamois is sourced from Cytech / Elastic-Interface affiliated Tier-1 European suppliers, with 3-density zoning and 12-panel flatlock attachment as the standard build.
| Chamois Spec | Berun Cycling Standard | What to verify before signing a chamois vendor |
|---|---|---|
| Supplier source | Italian-source (Cytech / Elastic-Interface affiliated, Tier-1 European supplier) | Ask for Tier-1 European-affiliated supplier disclosure on file (e.g., Cytech / Elastic-Interface). |
| Density zoning | 3-density gradient: 80 kg/m³ sit-bone / 60 kg/m³ perineum / 40 kg/m³ edge | Confirm a 3-density gradient zoning is spec’d, not a single density throughout. |
| Gender mold | Separate male / female / unisex molds, anatomically distinct | Check that gender-specific molds are available, not a single unisex pad. |
| Cover fabric | 80-denier suede-coated polyester, anti-bacterial, 30,000+ Martindale cycles | Confirm cover fabric ≥80-denier with documented abrasion testing. |
| Attachment | 12-panel flatlock seam, full perimeter sewn-in to bib body | Verify full-perimeter flatlock seam attachment, not a glue-only perimeter. |
| Endurance test | 6-hour continuous-ride simulation, zero pressure-point fail criterion | Ask for an in-house endurance test record (≥6 hr continuous-ride simulation). |
| Sit-bone landing | Anatomical sit-bone pocket molded into pad | Confirm an anatomical sit-bone pocket is molded into the pad rather than left flat. |
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.
Reflective engineering
360° Reflective Placement: Where Headlights Land on a Rider in Motion
Reflective placement is visibility engineering, not decoration. Each location below maps to the specific point where a car’s headlights catch a moving rider — ankle, center back, shoulder, side calf — with the material type, hand-feel impact, and best-fit SKU spec’d per placement.
| Placement | Why it matters for a rider in motion | Reflective material type | Hand-feel against base fabric | Wash-protocol durability | Best-fit SKU |
|---|---|---|---|---|---|
| Ankle rotation zone | Headlight catch is highest at the ankle through the pedal stroke (continuous 60–90 rpm rotation creates a flicker that a driver’s eye locks onto faster than a steady highlight) | Heat-applied reflective transfer film | Bonded to tight cuff, no rigid edge against skin | Bench-tested against the base-garment wash protocol before approval | bib tights · winter tights · leg warmers |
| Center back panel | The primary capture surface for headlights on a rider in drop-bar posture, where shoulders rotate forward and the back panel becomes the largest rear-facing target | Printed reflective ink on the sublimation panel | Zero-add hand feel (integrated with the sublimation print) | Ages with the base sublimation print, no separate adhesive layer | long-sleeve jersey · vest · thermal jacket |
| Shoulder line | Cross-traffic visibility — the angle at which side-approaching vehicles read the rider, where the shoulder is the highest fixed point on the kit | Reflective piping or heat-bonded tape | Minimal raised edge, sewn into the panel seam | Bench-tested against the base-garment wash protocol | vest · wind gilet · long-sleeve |
| Side calf / lower leg | The low-position headlight reflection zone for high-speed cars, where the calf is the closest point to road-grade light spread on a tucked rider | Heat-applied tape strip | Bonded to tight stretch fabric, no perimeter stitch lifting | Bench-tested against the base-garment wash protocol | bib tights · leg warmers |
Failure Modes → Fixes
Three Cycling Failure Modes Our Process Engineers Out: Chamois Fit, Within-Batch Drift, Multi-Vendor Patchwork
Cycling buyers raise the same three breakdowns repeatedly: chamois fit, within-batch sublimation drift, and the multi-vendor color patchwork that catches teams sourcing kit pieces from separate suppliers. Each opens a pre-bulk gate in our process detailed below.
1 Chamois Bunching and Saddle Sores
Pain
Chamois bunched, cover ripped, multiple riders reported saddle sores
An 80-rider charity-ride team courier’d us a failed bib: chamois bunched at the inseam after the first training ride, cover fabric ripped inside 2 hours, multiple riders flagged saddle sores by event day one, and the chargeback ran into the thousands.
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 off-shade in daylight
A road racing club ordered 12 jerseys plus 12 bibs in team navy. The season-opener photo showed three jerseys printed off-shade in daylight, and a sponsor logo drifted 2–3 mm across panel seams. The category sponsor cancelled the season’s 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, mismatched navy, sponsor logos peeling
An amateur club organizer assembled a kit via four vendors — jerseys and bibs from one factory, vest and warmers from another, a local screen-printer for sponsor logos, and drop-shipped winter tights. Sponsor logos peeled within the first season, the navy diverged across three pieces, and the rider feedback turned negative before the second ride.
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. The Cycling Team Pack runs the whole 600-piece, six-SKU kit as one engineered program on one PO. Summer Q1, shoulder Q2, winter Q3 — same Pantone reference across all three deliveries.
Request a 24-hour cycling kit spec match
Send your design brief or tech-pack with discipline and kit composition. Fabric, chamois spec, and a reserved sublimation-line slot come back confirmed within one business day.
Four production paths
From Tech-Pack to Team Pack — Four Ways to Produce a Cycling Kit
Four production models. The Cycling Team Pack is the site’s only cycling-specific service that bundles a full 6-SKU annual kit (jersey + bib + long-sleeve + tights + vest + warmers) into one PM, one PO, one color story.
OEM (Cut-and-Sew)
Your tech-pack, our cut-and-sew lines, full custom control.
- Race-fit or club-fit blocks graded to your spec
- Chamois integration on the bib line
- AQL 2.5 inspection before 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.
- 40+ cycling-cut block patterns
- Gender-specific chamois molds in stock
- 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.
- Existing cycling blank library
- Branded blanks ready for hangtag, care-label, and sponsor placement swap
- Sponsor placement applied in-house
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 — 600 pieces treated as a single engineered program. Single dye batch, single sublimation pass, single QC sign-off across summer / shoulder / winter.
- 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
Five Production Stages Between Your Design Brief and a Finished Team Kit
Five steps. Two are cycling-specific (rider try-on at chamois pre-bulk and cross-SKU sublimation batch sample). Single-SKU runs 35–42 days stock fabric / 48–58 days custom fabric; Cycling Team Packs are scheduled for staged summer/shoulder/winter delivery, with the program timeline confirmed line-by-line at RFQ.
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, fabric in stock, and reserve a dated slot on the sublimation line. 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. Rider try-on is the gate; lab-dip approval alone does not catch chamois inseam bunching or perimeter shift.
Layered on top of the baseline OEM cycle (see /services/oem); brands not building cycling kit can jump to the next section.
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. The sample set goes out by courier the day registration measurements clear.
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 + final QC pull + ship Day 22–47 stock / 33–58 custom
Cut-and-sew across dedicated lines (sublimation + chamois integration + cut-sew) under one PM. Per-piece sublimation ΔE check at sublimation station. Sampled inspection before release. Third-party inspection (BV / SGS / Intertek) on request. FOB your designated port.
End-to-end total: 35–42 days (stock fabric, single SKU) / 48–58 days (custom fabric). Cycling Team Packs are scheduled for staged summer/shoulder/winter delivery; the program timeline is confirmed line-by-line at RFQ.
FAQ
Cycling Sourcing, Answered
Eight questions across two buyer types: DTC cycling brands (pattern, reflective, chamois sourcing, color drift) and amateur teams (ODM no-tech-pack, Team Pack mechanics, sponsor logo registration, season-opener timing).
Group A — For DTC cycling brands
What separates your race-fit and club-fit patterns?
Race fit is cut for the drops: shorter front torso, longer back hem, sleeves set for a horizontal forearm. Club fit relaxes chest and waist circumference and lifts the front hem for an upright posture. Both come off the same 16-person pattern team and share one chamois platform, so a club can mix the two fits inside one team order without color or pad differences.
Can you build reflective night-visibility detailing into jerseys and tights?
Yes. Heat-applied reflective tape and printed reflective accents are standard options on long-sleeves, tights, and vests. Placement follows 360-degree visibility logic — ankle rotation zones, center back, shoulder lines — the points where headlight catch is highest on a rider in motion. Reflective trims ride through the same wash protocol as the base garment before approval.
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 actually work?
It treats a full annual kit as one engineered program rather than six separate runs: all six SKUs cut against a single master spec, matching-color pieces pulled from one dye batch, one PM and one invoice, delivery staged summer Q1 / shoulder Q2 / winter Q3. MOQ mechanics, sample terms, and lead times sit on the company FAQ.
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. Single-SKU sub-program runs 35–42 days stock fabric / 48–58 days custom fabric end-to-end through brief intake → chamois try-on → lab dip → sublimation batch sample → bulk. Each additional SKU adds schedule that is confirmed line-by-line at RFQ. For a 3-month window: prioritize the summer kit (jersey + bib + warmers) for season-opener delivery, with shoulder and winter staged behind it under the same PO.
Trust & Compliance
The Two Cycling-Specific Engineering Systems: 12-Panel Pattern Construction + 360° Reflective Placement
Compliance file: the five audited certifications we carry are catalogued by registry ID on the about page. Two cycling-track systems — sublimation registration and chamois pad sourcing — back up the engineering walked through below.
12-panel pattern construction graded against on-bike posture, not standing posture
A bib short carries 12 panels, each curved for a riding posture rather than a standing one. Our 16 in-house pattern-makers grade every block against on-bike measurements — hip angle closed, shoulders rotated forward — and position the gender-specific chamois mold inside the pattern itself, sewn into the bib body via 12-panel flatlock attachment.
360° reflective placement: ankle rotation, center back, shoulder line — the points where a car’s headlights land on a rider in motion
Heat-applied reflective tape goes on after sublimation and before assembly, so it bonds to flat fabric and survives the full wash protocol. We place reflectivity where a car’s headlights actually land on a moving rider — ankle rotation, the center back panel, the shoulder line — and the in-house lab, staffed by 8 technicians, verifies tape adhesion on every production batch alongside its ΔE and colorfastness readings.
“
We tried four vendors in 2024 — jerseys from one, vest and warmers from another, sponsor logos heat-pressed locally, winter tights drop-shipped. The navy didn’t match across pieces and the season was a write-off. 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.
Riding with us this season: a Gran Fondo organizer outfitting roughly 600 event participants, a German amateur road club on its second annual kit, and two DTC cycling labels running rPET capsules under our GRS scope. Customer names are shared in private reference calls, not printed on walls.