How Custom Cycling Kits Are Designed: From Concept to Finish Line

A team showing off how custom cycling kits are designed by Borah Teamwear.

April 7th, 2026 | Borah Teamwear

There is nothing quite like the feeling of “New Kit Day.”

You know the moment. The box arrives, the tape is cut, and your team finally gets to hold the jerseys you’ve been dreaming about for months. And suddenly, the whole squad looks—and feels—faster.

But have you ever wondered how custom cycling kits are designed before they reach your team? Long before those kits hit the dirt or the tarmac, they start as a simple idea. At Borah Teamwear, we don’t just pull stock jerseys off a shelf and slap a logo on them. Every custom piece is built from the ground up right here in our Wisconsin factory.

Here is the behind-the-scenes look at how your team’s vision goes from a blank canvas to the finish line.

Step 1: Concept and Design

Every great kit starts with a story. Maybe it’s your high school NICA team’s mascot, your local club’s classic heritage colors, or a wild neon pattern for a charity gravel ride.

The process begins when you bring that spark to our in-house design team. You don’t need to be an artist to get started. Whether you have a fully finalized vector file, a rough sketch on a napkin, or just a mood board of ideas, our graphic designers work directly with you to dial in the details. We tweak the color palettes, place the sponsor logos perfectly, and provide 3D mockups so you know exactly how the kit will look in the saddle.

Step 2: Getting it on Fabric

Once you sign off on the design, the digital file heads out to our factory floor. This is where the science happens.

We use a process called dye sublimation. Instead of printing ink on top of the fabric (which cracks and peels over time), we print your design onto special transfer paper. Then, using massive, high-heat presses, we turn that ink into a gas that bonds directly with the fibers of our premium Italian fabrics.

The result? The fabric stays incredibly breathable, the colors remain fade-resistant even after a hundred washes, and the design becomes a permanent part of the kit.

Step 3: Cut and Sew

This is where our “Made in USA” roots truly shine. While many brands ship their production overseas, our kits are cut and sewn right here in Wisconsin by our team of expert craftspeople.

Precision is everything. A race-fit jersey or a compressive bib short requires exact paneling to ensure it moves dynamically with your body. Our cutting machines cut the printed fabric with laser precision, and our sewing team meticulously stitches every seam, zipper, and chamois pad into place.

Step 4: The Finish Line

Before anything leaves our doors, it goes through a quality assurance check. We inspect the stitching and ensure the colors match your original proof. Only then is it boxed up and shipped to your doorstep.

From the first design consultation to the final stitch, the entire process is handled under one roof. That is how we guarantee the quality, maintain our fast turnaround times, and ensure that when your team lines up at the start line, you look exactly the way you envisioned.

Now that you know how custom cycling kits are designed, are you ready to get your team in gear for the upcoming season?

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