Market Trend Insight: From Cut-and-Sewn to Seamless to Fully Industrialized Viscose Underwear

The underwear industry is evolving faster than ever. Over the past decade, global markets shifted from traditional cut-and-sewn cotton underwear to seamless nylon-spandex designs. Now a new and more technologically advanced category is emerging: fully industrialized viscose underwear.

This new generation of underwear is not just softer or more comfortable—it represents a manufacturing revolution. It enables automation across the entire production chain, reduces defect rates, increases capacity, lowers costs, and delivers premium quality at scale. This article explains why viscose underwear is becoming the future of global OEM/ODM production.

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1. Stage One: Cut-and-Sewn Underwear (Traditional Manufacturing)

Cut-and-sewn underwear has long been the foundation of the global underwear market.

Characteristics:

• Cotton or cotton-spandex fabrics
• Manual cutting, stitching, and assembly
• High labor dependency
• Higher defect rates due to manual alignment
• Limited elasticity and shaping

Advantages:

• Low material cost
• Strong familiarity in developing markets
• Simple production structure

Limitations:

• Labor-driven and difficult to scale
• Inconsistent quality due to manual processes
• Not suitable for high-volume e-commerce brands
• Higher return rates due to fit inconsistencies

As labor costs rise globally, cut-and-sewn underwear becomes less competitive compared to more automated production.

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2. Stage Two: Seamless Underwear (Semi-Industrialized Automation)

Seamless underwear revolutionized global markets by introducing partial automation and a modern, stretchy fit.

Characteristics:

• Nylon/spandex tubular knitting
• Minimal seams
• Cleaner look with superior comfort
• Lower defect rate compared to cut-and-sewn
• Strong for athleisure and e-commerce markets

Advantages:

• Fits multiple body shapes with fewer SKUs
• Lower return rates
• Soft and lightweight
• Factory capacity highly scalable due to machine knitting

Limitations:

• Not fully automated—still requires sewing for crotch areas
• Yarn costs remain high
• Dyeing uniformity can be challenging
• Some regions still prefer cotton-like touch

Seamless remains strong, but viscose introduces a new dimension: full industrialization.

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3. Stage Three: Industrialized Viscose Underwear (The Future of Mass-Market Production)

Viscose underwear is emerging as the next major category due to its unique combination of comfort and industrial scalability.

Consumer-driven reasons:

• Feather-soft touch
• Excellent breathability
• Natural, premium feel
• Moisture control
• Cooling sensation suitable for hot climates

But the TRUE driver of growth is manufacturing evolution. Viscose allows complete industrialization of underwear production.

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4. Why Viscose = Full Industrialization (The Core Advantage)

Viscose underwear enables an automated, stable, and high-output production process that surpasses both cut-and-sewn and seamless.

4.1 Fully Machine-Based Production

Unlike cotton cut-and-sewn or nylon seamless:

• Fabric reacts consistently in cutting
• Automated sewing machines achieve perfect seams
• Fewer manual adjustments
• Less variation between batches

4.2 Lower Defect Rate

Cut-and-sewn: prone to human error
Seamless: prone to tension variation
Viscose: stable fabric behavior allows:

• Perfect alignment
• Clean seams
• Predictable shrinkage and stretch behavior

Lower defects → lower waste → lower cost.

4.3 Higher Capacity (Mass Production Ready)

Viscose manufacturing lines can run faster and longer with:

• Fewer stoppages
• Minimal recalibration
• Reduced dependency on skilled sewing labor

4.4 Significant Cost Reduction

Industrialization leads to:

• Lower labor cost per unit
• Fewer defective pieces
• Improved material yield
• Faster turnaround times

This makes viscose underwear premium in feel but highly competitive in price.

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5. Why Global Markets Will Shift Toward Viscose

Each region has unique motivations:

South America:

• Consumers love soft, silky materials
• Viscose feels premium at lower price than modal

Europe:

• Sustainability-driven market
• Prefers breathable, natural-feel fabrics

Middle East:

• Cooling and moisture-wicking are essential
• Viscose feels naturally suitable for hot climates

Africa:

• Stable quality and durability matter
• Viscose maintains shape better than cheap cotton

North America:

• Rapid growth of comfort-driven brands
• High demand for modal-like feel without modal-level cost

Viscose meets global needs at scale.

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6. OEM/ODM Benefits for Private-Label Brands

Viscose underwear helps brands:

• Scale quickly with stable production
• Offer premium comfort at accessible pricing
• Reduce return rates due to consistent fit
• Build strong brand identity around softness & comfort
• Run larger campaigns with predictable supply

Perfect for:

• Supermarkets
• Importers
• E-commerce brands
• Private-label retailers

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Conclusion

The underwear industry is transitioning through three clear phases: Cut-and-sewn → Seamless → Fully Industrialized Viscose.

Viscose underwear represents the next major industry shift because it enables:

• Full automation
• Lower defect rates
• Higher production volume
• Lower long-term costs
• Premium comfort that consumers want

Yejie Underwear supports global brands with viscose product development, automated production lines, and market-specific insights—helping clients stay ahead of the next global underwear trend.