The Development Phase

Inspiration → designs → fabric selection → patterns → tech packs — in the clothing business, this is called the development phase.

For me, this process was an insane learning curve, but it was incredibly rewarding and fun, too.

From Vision to Vintage-Inspired Sportswear

First comes gathering your inspiration pictures and mood boards. This is where I really honed the style I wanted to create for PIK Activewear. It was simple for me: pickleball had its first big boom in the 1970s, so a vintage, old-school aesthetic felt natural. Today’s consumers love thrifted finds and retro vibes, so I leaned into this style. Think the original Adidas look, ‘70s and ‘80s tennis court styles, and those perfect, color-blocking details from the era.

Designing Pickleball Apparel with Purpose

Next came turning these ideas into reality by working with a designer.  We had at least six rounds of design edits to perfect our Classic Collection.

The original designs had a more vintage fit, particularly the polos. For example, the women’s polo originally had longer sleeves with a slight puff at the bottom, while the men’s polo featured a wider collar. The skort design started as a straight-across style but evolved into the wrap style you’ll see in the final collection.

Feedback played a massive role in these iterations. Players and community members voiced their preferences in my early days of market research, leading to thoughtful additions like hidden pockets and side slits in the polos and shorts. This feedback was invaluable in creating practical, comfortable, and stylish activewear.

From Patterns to Production: Building Real Sportswear for Real People

Once the designs were finalized, they went to the pattern maker. The pattern maker transforms the designs into precise clothing patterns by determining the measurements and scale for each detail: collars, pocket sizes, trim width, hem width, and more. This was done for each article of clothing, in the size that you choose to be your sample piece. I chose my size (medium) and my husband’s size (large) for the women’s and men’s sample patterns. 

Once this is complete, the grading process happens. This is when the pattern maker takes the sample patterns and adjusts the measurements down and up to get the specific details of all the sizes you are going to make for your collection. 

Bringing It All Together: The Tech Pack

After grading, development specs and pattern cards were created. These are like summary sheets, listing every measurement and detail for the manufacturer. All this information, along with fabric selections, was compiled into what’s called a Tech Pack.

The Tech Pack is the holy grail of clothing production. It ensures manufacturers have every detail they need to create your designs exactly as envisioned.

Why It Matters

This activewear development process took me eight months, but it was definitely worth taking the time to do it right. By taking the time to perfect every step, I ensured the final product reflects what PIK Activewear stands for: stylish, comfortable, vintage-inspired sportswear designed for real people with real lives.

If you’re passionate about club sports & pickleball fashion, sportswear that suits you, or just love hearing about the behind-the-scenes process of creating made-in-USA activewear, follow along as I continue to share the journey!