You started with print-on-demand because it was low-risk. No inventory, no MOQs, just test designs and see what sells. But now you're feeling the squeeze—margins are thin, quality isn't consistent, and you can't customize beyond basic colors. Is it time to switch to cut & sew manufacturing?
Signs You've Outgrown Print-on-Demand
Not every brand needs to make the switch. But if you're experiencing these issues, it's time to at least explore cut & sew:
- Margins are too thin — You're selling products but barely making money after POD fees, platform cuts, and shipping
- Quality is inconsistent — Prints fade quickly, sizing varies between orders, fabric feels cheap
- You can't customize enough — Want custom tags, unique fabrics, special trims? POD won't cut it
- You're selling consistent volume — If you're moving 100+ units per design per month, you have the data to forecast demand
- Customer complaints about quality — Reviews mention thin fabric, poor print quality, or sizing issues
What Cut & Sew Actually Requires
Before you jump ship, understand what you're getting into:
The Reality Check:
- MOQs (Minimum Order Quantities) — Expect 100-300 units per style/color. That's upfront inventory you're committing to.
- Tech Packs — You need production-ready files with measurements, construction details, and material specs.
- Longer Lead Times — 4-8 weeks for production vs. POD's 2-5 days. Plan ahead.
- Upfront Investment — You're paying for inventory before you sell it. Budget $2,000-$10,000+ depending on order size.
Decision Framework: Should You Make the Switch?
Use this framework to decide:
1. Volume Threshold
Are you selling at least 50-100 units per design per month consistently? If yes, you have enough volume to justify cut & sew MOQs.
2. Margin Comparison
Quick math:
- POD: $25 base cost + fees = $30 total → Sell at $50 → $20 margin (40%)
- Cut & Sew: $15 landed cost → Sell at $50 → $35 margin (70%)
If you can improve margins by 20%+, it's worth exploring.
3. Brand Positioning
Are you positioning as a premium or mid-tier brand? Premium brands need premium quality. POD often can't deliver that.
4. Cash Flow Reality
Can you afford to tie up $5,000-$10,000 in inventory for 4-8 weeks? If not, stay with POD until you build up cash reserves.
How to Transition Without Disrupting Sales
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1
Start with Your Best Seller
Don't switch everything at once. Pick your top-selling design and test cut & sew with that one product first.
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2
Run POD and Cut & Sew in Parallel
Keep POD running for new designs while you transition proven sellers to cut & sew. This gives you flexibility.
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3
Factor in Lead Times
Place your first cut & sew order 2 months before you expect to run out of POD inventory. This prevents stockouts.
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4
Test Quality First
Order samples before committing to bulk production. Make sure quality meets your standards.
Real Talk: Cut & Sew Isn't Always Better
Don't switch just because you think you "should." Here's when to stay with POD:
- You're still testing designs and don't have consistent best sellers
- You don't have $5,000+ in cash reserves for inventory
- You're selling less than 50 units per design per month
- You value speed and flexibility over margins (seasonal or trend-driven brands)
POD is a legitimate long-term strategy for some brands. If you're happy with the trade-offs, don't force a switch.
Need Help Making the Switch?
Transitioning from POD to cut & sew isn't simple—but we've done it dozens of times. We can help you source manufacturers, create tech packs, and manage your first production run.
Book a Strategy Session