Ready to Build Your Outerwear Range?
Tell us your target climate, your retail price point, down or synthetic, and your quantity. We’ll come back within 24 hours with a fill specification, shell recommendations and clear pricing.
Every puffer jacket quote you have ever received described the shell fabric and said nothing about the fill. That is backwards. The insulation is the product — the shell is the packaging around it. Axis Sportswear is a cut & sew custom puffer jacket manufacturer producing down, synthetic and hybrid-insulated outerwear for apparel brands, sports clubs, corporate buyers and retailers across the USA, UK and Europe.
Every jacket is specified properly — fill type, fill power, fill weight in grams, baffle construction, shell denier and DWR chemistry. You get a written spec, not an adjective. Minimums start at 50 pieces per style, tech pack development is free, and your first sample ships in 10–15 days.
Three things decide whether a puffer performs or gets returned: what is inside it, how much of it there is, and whether the construction lets it loft. We settle all three before anyone chooses a color.
Send a tech pack, a sketch, a competitor jacket, or just your target retail price and a mood board. Our design team returns a production-ready spec with shell denier, lining, insulation type, fill power, fill weight per size, baffle layout, channel width, zip specification, trim and every logo position marked. Free with every order, and you approve it before sampling starts.
Down gives the best warmth-to-weight ratio and compresses smaller than anything synthetic — but it loses almost all insulating value when wet and costs significantly more. Synthetic wadding keeps insulating when damp, washes easily, costs less and suits volume programmes, at the price of extra bulk and weight. A down blend or a hybrid mapping — down through the body, synthetic across the shoulders and hood where rain lands first — is often the right commercial answer and almost nobody offers it. Pick wrong for your climate and price point and the garment fails regardless of how good the shell looks.
Order one style or a full outerwear range. Everything below can run in the same shell fabric and colourway in a single production batch, so your collection reads as one line rather than four separate buys.
20D or 30D downproof ripstop with 60–80 g of insulation, stitch-through baffles and a jacket that stuffs into its own pocket or a supplied sack. The highest-volume seller in the category and the easiest entry point for a new brand, because the fabric cost is low and the perceived value is high.
The core commercial product: 40D shell, 100–150 g fill, hooded or collared, two-way zip and hand pockets. Warm enough for a European or Northern US winter without becoming an expedition piece. This is where most of your margin will come from.
Longline insulated parkas with 200–280 g fill, box-wall baffles, storm flaps, adjustable hoods and reinforced shoulder panels. Built for genuine cold — Canada, Scandinavia, the northern US and continental European winters.
Shell fabric on a puffer is measured in denier, not GSM, because yarn thickness is what determines tear strength, hand feel and whether the panel is downproof. Here’s our range with real figures. Ask for a physical swatch pack before committing to a season buy.
Outerwear ties up more cash per unit than any other garment category, so the order structure matters as much as the unit price.
50 units per style and colourway, with sizes mixed freely inside that quantity. Enough to test a silhouette in one market without committing a full season's budget to a category where the per-unit cost is high.
Breakpoints at 200, 500, 1,000 and 2,500 units per style. On puffers the savings at volume are larger than on any other product we make, because insulation and trims are bought in bulk and the fabric minimums drop sharply.
Run a jacket, a vest and a longline coat in the same shell fabric and colourway in one production batch and the fabric minimum, the dye lot and the setup cost are shared across all three. For an outerwear capsule this is normally the single largest saving available, and it also guarantees your colours match across the range — which they will not if you order them in three separate runs.
If you’re an outerwear brand, a retailer or a uniform supplier, we manufacture under your label, not ours. Nothing that leaves our floor carries our name.
Down and feather content labelling is legally specified and differs by region — get it wrong and a shipment can be held at customs or pulled from a retailer’s floor. We format it correctly for your market before the labels are printed.
A new label testing one packable puffer before committing to a winter buy, a football club ordering fifty bench jackets, a facilities company kitting out four hundred staff, and an established outerwear brand planning a full AW range are four completely different orders. We price and schedule all four the same way — transparently, and without treating a 50-piece order as a nuisance.
Start with one style and one colourway to prove the fit and the fill weight in your market, then scale into a full range once you have sell-through data. Pricing scales with volume, patterns and fill specs stay on file, and reorders skip development. There’s no penalty for starting small and no ceiling on where it goes.
No surprises, no middlemen, no guessing about where your order is. Here’s exactly how we work.
Quick, clear response to your inquiry. Reach out and our team replies within 24 hours with the right questions and next steps.
We learn your colors, logo, fabric preference, sizing and deadline, then build a print-ready mockup.
You get clear, quantity-based pricing up front — no hidden costs.
We produce a sample for you to review and approve before the full run. We match your exact Pantone/hex colors at this stage.
Once you approve, we manufacture your order and align delivery to your season or event deadline.
Every piece is inspected, then finished with your brand label and packaging.
Your order ships sorted and labeled, with tracking — and we follow up to make sure you’re happy.
Different teams need different finishes. We offer every major decoration method in-house:
Embroidering directly through a filled panel perforates the shell and the down starts escaping through the needle holes. The correct method is to embroider onto a separate patch or a pre-quilted panel and attach it, or to place the embroidery on an unfilled area such as a collar, cuff or yoke seam. If a supplier offers direct embroidery on a filled down panel without qualification, they have not made many puffers.
The workhorse method for puffers. Thin, flexible and applied at a controlled low temperature suitable for nylon, which scorches and glazes at the temperatures used for cotton. Excellent for logos, sponsor marks and reflective hits.
Applied with adhesive or stitched only through the seam allowance so the chamber stays sealed. The most durable branding option on outerwear and the standard on premium technical jackets.
Possible on flat panels with the right ink system for coated nylon, but it cracks on a highly quilted face and generally reads cheaper than a transfer or a badge. We'll be honest about when it's the wrong call.
All-over print is available on polyester shells only. Sublimation will not bond to nylon, so if you want a full-print puffer the shell choice is made for you at design stage rather than discovered at sampling.
A logo formed by the quilt stitch pattern itself, or heat-debossed into a coated shell. Subtle, permanent, adds no components, and increasingly what premium outerwear brands are choosing over an applied badge.
We exist to make ordering custom outerwear specific, honest and worth repeating season after season.
Tell us your target climate, your retail price point, down or synthetic, and your quantity. We’ll come back within 24 hours with a fill specification, shell recommendations and clear pricing.
We manufacture premium custom sportswear, activewear, and team uniforms for brands worldwide, combining high-quality fabrics, full customization, and reliable wholesale production.
Copyright © 2026 Axis Sportswear. All rights reserved.
Axis Assistant