Have you ever been curious about how custom cycling gear is manufactured? I had the opportunity to visit the Alé Bikewear factory in Italy to witness the entire production process firsthand. This journey takes you from the initial stages of selecting raw fabrics and digital design through the precise steps of cutting, printing, and final assembly. It’s within these walls that high-performance cycling jerseys and bib shorts are born, embodying a fusion of Italian artistry and cutting-edge performance technology.
In the accompanying video, I walk through the complete custom kit creation process. This includes the design and ordering phases, followed by a detailed look at each production step. We observe the cutting of fabrics, the sublimation printing technique, and the complex sewing stages required to produce professional-level cycling apparel, all in a unique design crafted specifically for PEZ.
When I began cycling in the 1980s, the concept of “custom” cycling apparel as we know it today was virtually nonexistent. The closest we came was when a friend’s mother would sew a few jerseys for us using basic polyester material from a local fabric store.
However, advancements like sublimation printing—the method of transferring dyes from paper to fabric—and the digital revolution have since transformed the industry, enabling possibilities that were once mere imagination.
When I founded PEZ, one of my long-held aspirations was to create our own custom cycling kit. This is a dream shared by many cyclists who prefer to express their personal style rather than simply promoting another brand. With custom apparel, everyone has the chance to become their own brand, a concept I find quite appealing.
We have been reviewing and wearing Alé kit for many years and have visited their Italian headquarters and factory on several occasions. However, this marks our first collaboration to produce a custom kit specifically for PEZ.
Our collaborative process commenced in the spring with a series of emails, followed by a direct conversation with their designers to discuss concepts and ideas for the kit’s aesthetic. A couple of weeks later, they presented several design options, which we then refined together.
Once I approved the design, their team took over the production. This involved translating our initial design into production files, ensuring the kit would maintain a consistent appearance across all sizes, from XS to XXL. This means that logos and color lines must align perfectly across a wide range of measurements.
During my visit in June, following the Alé La Merckx gran fondo, I had the opportunity to observe the entire production process from the initial digital drawings to the finished product. This included gaining insight into the precise methods professional athletes use to fold jerseys and bib shorts to fit perfectly into their gear bags.
The manufacturing process is highly intricate and involved, yet it has been refined into a science. It is managed by skilled artisans and technicians who expertly blend traditional Italian tailoring and craftsmanship with the latest production techniques. This ensures that equipping your team, club, or group of friends with a unique, personalized look is a straightforward endeavor.
Personally, I find the process of creating new cycling apparel incredibly rewarding. I have distilled this experience into a 20-minute video to provide a clear demonstration of each step involved. However, the most satisfying part is undoubtedly the experience of wearing the finished product.
• Find more information on Alé Bikewear Custom Kit here.