How the Iconic Birkie Bibs Are Made

Photo by: James Netz

Every winter, the American Birkebeiner transforms Hayward into the epicenter of cross-country skiing. You wear your bib on the trail for a few grueling hours, but it usually hangs on your wall for years.

As the official bib supplier for the 2027 American Birkebeiner, Borah is incredibly proud to play a role in that tradition. But outfitting an event of this scale is a massive undertaking. Every single one of the nearly 15,000 race bibs is handcrafted from scratch right here in our Wisconsin factory.

Before you hit the groomed trails, here is a behind-the-scenes look at exactly how your Birkie bib comes to life.

Step 1: Artwork and Digital Setup

The process kicks off when our art department collaborates directly with the Birkie Foundation to finalize the wave designs and color palettes for the year.

Once approved, each of the 15,000+ race bib print files are created, adding text and numbers specific to each individual skier. Once the digital data is prepped and organized, the files are ready for print.

Step 2: Print and Transfer

First, the digital files are printed onto specially coated recycled transfer paper. That paper is then fed into our heat presses alongside our blank technical fabric. Heated to 400 degrees, the ink sublimates—meaning it turns into a gas and permanently dyes the fibers of the fabric.

Because the design is infused directly into the material, it will never crack or fade. It also allows us to use a lightweight, high-performance technical fabric that naturally moves moisture away from your body to keep you warm and dry during the race.

Step 3: Cut and Sew

Once the transfer is complete, the rolls of printed fabric are sent to our cutting table, where they are scanned and cut to precise measurements.

The cut fabric panels are handed off to our in-house sewing team. With incredible skill and precision, our team sews every single one of the 15,000+ bibs together. We take immense pride in manufacturing high-performance apparel right here in Wisconsin, and getting to build the gear for the nation’s premier cross-country ski event is a highlight for our entire production floor.

Step 4: Inspection and Shipping

The final step before the bibs head north! After sewing is complete, every bib runs through our inspection department. Our team carefully reviews the stitching, verifies the print quality, and organizes the bibs by wave and number.

Once everything is boxed up, they are shipped out for final delivery, ready and waiting for you at bib pick-up.

We could not be more excited for the 2027 American Birkebeiner. Best of luck to all the participants this year!

Suit Up for the Birkie

Need a race suit for the Birkie? Head over to the Borah Nordic Race Suit Colorizer, pick one of our design templates, and drop in your colors. We’ll handcraft a custom suit just for you right here in Wisconsin.

Nordic Suit Colorizer