Sample Quality Checklist is used to ensure that samples (like proto samples, fit

samples, PP samples, etc.) meet the required standards before mass production begins.
Here’s a comprehensive checklist covering key aspects:

1. General Inspection

✅ Style & Design – Matches approved tech pack, sketches, and buyer specifications.
✅ Fabric – Correct type, weight, color, and quality as approved.
✅ Trims & Accessories – Buttons, zippers, labels, and embellishments match
requirements.
✅ Measurements – Within tolerance as per size chart (check critical points like chest,
waist, length, sleeve, etc.).
✅ Stitching – Even, consistent stitch length, no skipped stitches or loose threads.

2. Construction & Workmanship

✅ Seams – Properly aligned, no puckering, reinforced where needed (e.g., stress

points).
✅ Hems – Even width, properly folded, and stitched.
✅ Closures – Zippers, buttons, snaps, and hooks function smoothly and are securely
attached.
✅ Pockets – Correct placement, size, and stitching; no misalignment.
✅ Pleats, Darts, and Gathers – Evenly distributed and properly stitched.

3. Finishing & Aesthetics

✅ Pressing & Steaming – No wrinkles, shine marks, or creases.

✅ Thread Trimming – No loose threads or untrimmed excess.
✅ Labels & Tags – Correct placement (size, care, brand labels), legible printing.
✅ Print/Embroidery – Aligned, no smudging, correct colors, and durability.
4. Functional Testing (if applicable)

✅ Fit & Comfort – Garment fits the intended body shape (test on fit model if
required).
✅ Stretch & Recovery – For knits and stretch fabrics, ensure proper elasticity.
✅ Colorfastness – No bleeding or fading (check after wash test if required).
✅ Durability – Seams and stress points hold under tension.

5. Compliance & Documentation

✅ Safety Standards – No sharp objects (pins, needles) left in garment.

✅ Regulatory Requirements – Meets legal standards (e.g., flammability, chemical
compliance).
✅ Packaging – Folded/packed as per buyer’s instructions.
✅ Approval Status – Signed off by QC, merchandiser, and buyer if needed.

Final Verification

✔ Overall Appearance – No defects, meets buyer’s aesthetic expectations.

✔ Revisions Needed? – If issues found, document corrections for next sample.

This checklist helps prevent costly errors in bulk production by catching issues early.
Different buyers may have additional specific requirements, so always cross-check with
their guidelines.

Activewear Sample Quality Checklist

Activewear requires extra attention to fit, functionality, and durability due to its high-
performance nature. Here’s a specialized checklist to ensure quality in sportswear, gym
wear, athleisure, and performance apparel:
1. Fabric & Material Quality

✅ Fabric Composition – Correct blend (e.g., polyester-spandex, nylon-elastane) as per

tech pack.
✅ Stretch & Recovery – Fabric stretches adequately and returns to original shape
without sagging.
✅ Moisture-Wicking – Tested for sweat absorption and quick drying (if required).
✅ Breathability – Mesh panels or ventilation zones properly placed.
✅ Color & Print – No bleeding, cracking, or fading (check after wash test).
✅ Fabric Defects – No snags, holes, or uneven dyeing.

2. Construction & Stitching

✅ Seam Type – Flatlock, overlock, or coverstitch as specified (prevents chafing).

✅ Reinforced Stress Points – High-tension areas (armholes, crotch, waistband) have
double stitching or bar tacks.
✅ Elastic/Binding – Evenly applied, not too tight or loose (check cuffs, waistbands, leg
openings).
✅ Lay Flat Collar & Necklines – No twisting, smooth finish.
✅ Flat Seams – No bulky stitching that could irritate skin during movement.

3. Fit & Functionality

✅ Range of Motion – Test on a fit model (ensure no restriction in movement for yoga,
running, etc.).
✅ Compression (if applicable) – Proper tension for muscle support without
discomfort.
✅ Gussets & Articulated Knees – Correct placement for flexibility.
✅ Reflective Elements – Properly aligned and securely attached (if required for safety).
✅ Zippers & Pockets – Smooth operation, secure closures (no gaping in sports bras or
leggings).

4. Finishing & Aesthetics

✅ Laser-Cut or Tagless Labels – No scratchy tags (common in performance wear).

✅ Print/Embroidery Durability – Stretch-friendly prints that don’t crack when
stretched.
✅ Odor & Antimicrobial Treatment – If specified, verify effectiveness.
✅ Pilling Test – Fabric resists pilling after abrasion (rub test).

5. Performance Testing (If Required)

✅ Wash Test – No color bleeding, seam slippage, or shrinkage beyond tolerance.

✅ Stretch Test – Fabric and seams maintain integrity after repeated stretching.
✅ Lightfastness – Prints/colors don’t fade under UV/sunlight (for outdoor activewear).
✅ Sweat & Chlorine Resistance – For swimwear or high-intensity wear.

6. Compliance & Safety

✅ Chemical Compliance – Free from harmful substances (e.g., AZO dyes, PFAS).
✅ Flammability Standards – Meets regulations (especially for children’s activewear).
✅ Nickel-Free Trims – No skin irritation from snaps or zippers.
 Final Approval

✔ Wear Test Feedback – If possible, test in real conditions (e.g., gym, running).
✔ Buyer’s Comments Addressed – All revisions from previous samples corrected.
✔ Packaging & Labeling – Polybags, hangtags, and barcodes as per requirements.

Why This Matters for Activewear

• Poor stitching/seams can lead to blowouts during exercise.

• Incorrect stretch recovery causes sagging after wear.
• Non-breathable fabric leads to discomfort and poor performance.

Performance Jacket Sample Quality Checklist

Performance jackets (e.g., running, hiking, training) require weather resistance,

breathability, and durability. Here’s a specialized checklist:

1. Fabric & Material

✅ Shell Fabric – Correct waterproof/breathable membrane (e.g., Gore-Tex, DWR

coating).
✅ Lining – Smooth, moisture-wicking, and non-abrasive.
✅ Insulation (if applicable) – Even distribution (e.g., synthetic fill or fleece).
✅ Stretch Panels – Proper placement for mobility (underarms, back).
✅ Reflective Elements – Securely attached and visible in low light.

2. Construction & Stitching

✅ Seam Taping – Fully sealed (no gaps) for waterproofing.

✅ Zippers – Water-resistant (e.g., YKK AquaGuard), smooth glide.
✅ Hood & Cuffs – Adjustable with secure toggles/elastic.
✅ Pockets – Waterproof zippers, correctly positioned (chest, handwarmer).
✅ Reinforced Stress Points – Bar tacks at pull points (zippers, drawstrings).

3. Fit & Functionality

✅ Range of Motion – No restriction when arms are raised or stretched.

✅ Ventilation – Pit zips/openings function properly.
✅ Hem & Waist Adjustability – Drawstrings or elastic stays in place.
✅ Hood Fit – Covers helmet (if needed) without obstructing vision.

4. Performance Testing

✅ Waterproof Test – No leakage under simulated rain (ISO 811).

✅ Breathability Test – MVTR (moisture vapor transmission rate) meets spec.
✅ Wind Resistance – No air penetration (for windbreakers).
✅ Wash Test – DWR coating remains effective after laundering.

5. Finishing & Compliance

✅ Labels – Care instructions, size, and brand tags correctly placed.

✅ Chemical Compliance – Free from PFAS, PFCs (if eco-friendly).
✅ Packaging – Folded with tissue paper, polybag, or hanger-ready.

Leggings Sample Quality Checklist

Activewear leggings must balance compression, flexibility, and durability. Key checks:
1. Fabric & Material

✅ 4-Way Stretch – Recovers shape after stretching (e.g., 80% nylon, 20% spandex).
✅ Opacity – No sheer spots when stretched (squat test).
✅ Moisture-Wicking – Quickly pulls sweat away (test with water droplets).
✅ Brushed Lining (if applicable) – Soft interior for warmth.

2. Construction & Stitching

✅ Flatlock Seams – No chafing or raised stitching.

✅ Gusset – Reinforced crotch for mobility (no seam splitting).
✅ Waistband – Wide enough to stay put, no rolling down.
✅ Ankle Cuffs – Snug but not restrictive (no gaping).

3. Fit & Functionality

✅ Compression Level – Medium/high compression holds muscles without pinching.

✅ Squat Test – No ride-up or transparency when bending.
✅ Pockets (if any) – Secure phone/key storage (e.g., side thigh pocket).
✅ Waistband Stay-Put – Doesn’t slide during movement.

4. Performance Testing

✅ Stretch Recovery – Returns to shape after 10+ stretches.

✅ Pilling Test – No fuzz after abrasion (Martindale test).
✅ Wash Test – No color bleed, seam twisting, or shrinkage.

5. Finishing & Compliance

✅ Laser-Cut Labels – No itchiness (common in high-end leggings).

✅ Eco-Certifications – Oeko-Tex, recycled fabric claims verified.
✅ Packaging – Folded with size sticker, polybag, or branded box.
 Key Differences Summary

Feature Performance Jacket Leggings

Critical Focus Waterproofing, breathability Stretch recovery, opacity

Seam Type Taped/sealed Flatlock or seamless

Fit Test Arm mobility, hood coverage Squat test, waistband hold

Special Tests Water column, MVTR Opacity, pilling resistance

Common Defects in Performance Jackets & Leggings (with Visual

Examples)

Here’s a breakdown of critical defects to watch for during inspection, categorized by

garment type:

🔴 Performance Jacket Defects

1. Fabric & Coating Issues

• Delamination – Inner membrane peeling away from shell fabric (compromises

waterproofing).
• DWR Failure – Water stops beading on the surface after washing (looks soaked instead
of rolling off).
• Uneven Insulation – Clumpy or thin areas in padded jackets.

2. Construction Defects

• Gaping Zippers – Zipper doesn’t lay flat, allowing wind/water penetration.

• Misaligned Seam Taping – Tape doesn’t fully cover stitch holes (leaks in rain tests).
• Loose Reflective Strips – Peeling or cracking after washing.
 3. Functional Failures

• Broken Drawcord Toggles – Snaps off during adjustment.

• Pit Zips Snagging – Zipper teeth catch fabric when opening/closing.
• Hood Billing Doesn’t Stay – Flops in wind despite adjustments.

4. Aesthetic Flaws

• Glue Stains – Visible adhesive from seam taping.

• Misprinted Logos – Smudged or off-center branding.

🔴 Leggings Defects

1. Fabric & Stretch Issues

• Sheerness – Becomes see-through when stretched (fails the "squat test").

• Knit Runs – Snags that create ladders in the fabric.
• Uneven Dyeing – Splotchy color (common in ombre prints).

2. Stitching & Seam Problems

• Crotch Seam Splitting – Bursts open during stretching (weak stitching or lack of
gusset).
• Rolling Waistband – Folds over during wear (elastic too tight or narrow).
• Puckered Hems – Wavy ankle cuffs from improper tension.

3. Performance Failures

• Pilling – Fuzzy balls form on inner thighs after abrasion.

• Faded Prints – Cracked or peeling after washing (common in sublimation).
• Compression Loss – Baggy knees/waist after minimal wear.
 4. Finishing Defects

• Exposed Elastic – Raw edges poke out at waistband or cuffs.

• Misaligned Labels – Care tags stitched into side seams (irritates skin).

📸 Visual Defect Examples (Hypothetical)

1. Jacket: Seam tape peeling like old wallpaper → Reject (waterproofing failed).
2. Leggings: Light visible through fabric when stretched → Reject (opacity failure).
3. Both: Thread tension uneven → Reject (loose stitches lead to seam failure).

How to Catch These Defects

• Jackets: Spray water on seams, check for leaks (home test: showerhead + tissue inside).
• Leggings: Stretch over a knee cap to check transparency.
• All: Rub fabric 10x with a white cloth to test dye transfer.

Defect Severity Grading Scale for Activewear

(Applicable to Performance Jackets & Leggings)

Defects are categorized by severity to determine whether a garment passes inspection

or requires rework/rejection. Below is a standard AQL (Acceptable Quality Level)-
inspired grading system:
 1. Critical Defects (0 Tolerance – Immediate Rejection)

Definition: Defects that endanger user safety, violate regulations, or render the
garment unusable.

Examples for Jackets:

• Broken zipper teeth causing sharp edges.

• Toxic chemical residue (e.g., lead in prints).
• Waterproof membrane delamination (fails rain test).

Examples for Leggings:

• Sheerness exposing skin in normal wear (fails squat test).

• Seam splitting at crotch (exposes wearer).
• Nickel in waistband snaps causing allergic reactions.

Action: 100% rejection – Entire batch must be reworked or scrapped.

2. Major Defects (Strict Tolerance – Usually 2.5 AQL)

Definition: Defects that significantly impact functionality, durability, or aesthetics,

likely leading to customer returns.

Examples for Jackets:

• Misaligned seam tape (leaks under heavy rain).

• Gaping armhole seams (allows cold air penetration).
• Reflective trim peeling after one wash.
 Examples for Leggings:

• Waistband rolling during movement.

• Pilling after light abrasion (visible on first wear).
• Misprinted logos (off-center or cracked).

Action:

• Fails inspection if exceeding AQL limits (e.g., >2.5% defects in batch).

• Defective units must be repaired or replaced.

3. Minor Defects (Higher Tolerance – Usually 4.0 AQL)

Definition: Defects that do not affect performance but slightly reduce visual appeal.

Examples for Jackets:

• Loose thread >1 cm (uncut).

• Minor glue stain (non-toxic, <1 cm diameter).
• Slight color variation in lining (not noticeable when worn).

Examples for Leggings:

• Stitch skip (1–2 mm, no seam weakness).

• Faint dye streak (only visible under bright light).
• Minor uneven hem (difference <0.5 cm).

Action:

• Accepted within AQL limits (e.g., ≤4% defects).

• Retailers may downgrade to "B-grade" for discount sales.
 How to Apply This Scale in QC Inspections

1. Define AQL Levels (e.g., 2.5 for major, 4.0 for minor defects).
2. Randomly Sample Batch (e.g., 32 pieces from 500).
3. Tally Defects per severity:

o If 1 critical defect → Reject entire batch.

o If major defects exceed AQL → Reject or negotiate rework.
o If minor defects exceed AQL → Buyer may accept with discount.

Real-World Example

Scenario: A shipment of 1,000 leggings has:

• 0 critical defects ✅
• 15 major defects (1.5%) → Passes (under 2.5 AQL).
• 50 minor defects (5%) → Fails (over 4.0 AQL).
Result: Buyer may request a price reduction or repair minor flaws.

Pro Tip

• Photograph Defects for clear communication with factories.

• Reference Tech Pack to distinguish "minor" vs. "major" (e.g., "logo misalignment >0.5
cm = major").

Eng / Ayman Mowafy