Hello, welcome to the Making of your Corduroy Workshirt. This page will be updated each week until we deliver your shirt.
Your shirt being finished.
After being dyed, there are a handful of jobs left to do to make sure your shirt is ready for you.
1. Quality checking.
2. Sewing on buttons.
3. Pressing & folding.
4. Packing up.
Watch the video below to see the last week in the factory, before your shirt makes it's way to you:
Your shirt being dyed.
Since last week's update your corduroy workshirt has been on a short journey up the road to Agostinho's dye house, to be transformed from a fully sewn, white shirt to either Smokey Pink, Oat, Navy or Pine Green.
It is safe to say it now looks a lot more like the shirt you ordered.
Watch the video below to see inside the dye house:
Your shirt being sewn.
With every piece cut, sewing begun in January in our family fun factory in Guimaraes, Northern Portugal. If you've been with us since Batch No.1, you may recognise some of the same faces.
Watch the video below to see the shirts as they're sewn, before they're dyed:
Cutting Your Shirt.
Late last year, each piece that makes up your shirt was cut. Cutting sounds straight forward, but actually the process is a complex one.
First, Sandra (the head of pattern making and grading) creates the cut plan. That means working out how to lay out each pattern piece before cutting begins, to be left with as little waste as possible.
Sandra works out the cut plan on her computer, laying out each piece for every size separately. It’s important that every piece of your shirt is cut from the same roll of fabric, so that they react in the exact same way when they're dyed.
Next the cut plan is printed to scale and laid over multiple layers of corduroy, stacked neatly on top of each other.
And then cutting begins. One piece at a time.
Our factory used to use an electronic cutting knife that could cut through 50 layers of fabric at a time, but during the pandemic they invested in a new robotic cutting machine which is more accurate than the human hand and means all the skilled roles within the factory are based on constructing the shirts themselves.