A tech pack is the single document that defines your product. It tells the factory what to make, what it should look like, and how to build it. A complete tech pack reduces sample revision rounds, prevents production errors, and saves months of back-and-forth.
This guide covers every section a motorcycle jacket tech pack needs, in the order factories use it.
Section 1: Cover page and product overview
The cover page establishes the basics so there is never any confusion about which product a tech pack relates to:
- Product name and style number
- Brand name
- Season and delivery date
- Target protection level (if CE-relevant: EN 17092 Level A, AA, or AAA)
- Revision number and date (version control is important — "Rev 3, 14 Oct" prevents the factory working from an outdated version)
Section 2: Sketch and technical flat
A technical flat is a line drawing of the garment showing every design detail: seams, panels, zips, pockets, vents, and closures. You need both a front and back view. The sketch does not need to be professionally illustrated — a clear, annotated hand sketch is enough for most factories if it shows every panel and construction detail.
What to annotate on the flat: seam positions, zipper locations and directions, pocket openings, vent positions, cuff and hem closures, collar type, and any logo or label positions.
Section 3: Materials specification
This is the most critical section of the tech pack. List every material used in the garment with enough detail for the factory to source it or confirm what they have in stock:
- Outer shell: material type (e.g., full-grain cowhide 1.0–1.2mm, or 600D Cordura), colour, and finish
- Lining: material (polyester taffeta, mesh, etc.), colour
- Thermal liner (if applicable): whether it is removable, attachment method
- Waterproof membrane (if applicable): type and whether bonded or inserted
- Stretch panels: material, position on garment
- Reinforcement panels: position and material (especially in impact zones for CE construction)
Section 4: Armour and protection specification
If your jacket is CE-relevant, the armour section determines whether your garment can achieve the target protection level:
- Shoulder protector: EN 1621-1 Level 1 or Level 2 (specify the brand if you have a preference)
- Elbow protector: EN 1621-1 Level 1 or Level 2
- Back protector: whether included, and if so EN 1621-2 Level 1 or Level 2
- Armour pocket positions and pocket opening style (side entry, top entry)
- Whether protectors are fitted as standard or supplied as an add-in for the consumer
Section 5: Hardware and trims
Every piece of hardware needs a specification. Vague hardware specs are a common cause of sample surprises:
- Main zip: length, direction, brand preference (YKK is the standard reference), colour, puller style
- Pocket zips: same detail for each pocket
- Sleeve zips (if any): length, position
- Velcro/adjustment straps: position, width, colour
- Buckles, D-rings, press studs: position and finish (nickel, antique brass, matte black, etc.)
Section 6: Label and branding
- Main brand label: position (back neck or left chest lining), size, attachment method (sewn or heat-applied)
- Care label: your brand's care label or the factory's standard care label
- Size label
- CE label (if applicable): required by EN 17092, must include protection level, size, and care instructions specific to CE requirements
- Country of origin label: "Made in Pakistan" — required for most markets
- Any woven patches or embroidery: position, size, colour reference
Section 7: Graded size spec
A size spec lists the body and garment measurements for each size you intend to produce. You need at minimum: chest, waist, hip, sleeve length, back length, and arm circumference at bicep and cuff. Grading rules (how much each measurement increases per size) are needed if you are ordering more than one size.
For a sample order, one size is enough. Specify which size the sample should be built to — most brands sample in a medium (size M or 50/52 EU).
Section 8: Construction notes
Any specific construction detail that is not obvious from the flat drawing. Examples: "double-needle stitching on all exposed seams", "armour pocket seams must be bar-tacked at each corner", "collar foam density minimum 30g/m²", "all zip teeth must be covered when zip is open".
CE construction notes belong here too: if your Level AA spec requires reinforcement stitching at zone boundaries, write it here explicitly.
What you do not need for a first sample
Factories can start a first sample without a fully graded size run, without final label artwork, and without a finished colour palette — these can be confirmed before production. A sample just needs enough detail to build one example of the garment in approximately the right construction and proportion. Do not delay starting a sample because your tech pack is not perfect. An imperfect sample from a well-described spec is worth more than a perfect tech pack you spend three more months refining.
Frequently asked questions
Do I need to hire a tech designer to write a tech pack?
No. A clear sketch with annotations, a materials list, and written construction notes is enough for most factories to work from. A professional tech pack speeds things up and reduces ambiguity, but a well-organised DIY tech pack is far better than no document at all. Many brands start sampling with a sketch and a spec sheet and produce the formal tech pack after the first sample is approved.
What format should a tech pack be in?
PDF is the standard format for sharing with factories. The factory cannot edit a PDF, which is what you want — it prevents accidental changes to the spec. Keep the source file (Illustrator, InDesign, Excel, or even a Word document) as your working version, and export a new PDF for each revision.
How detailed does the sketch need to be?
Detailed enough that a cutter who speaks no English can understand where every panel, seam, and opening is. If you are unsure whether a detail is clear, it probably needs more annotation. The sketch does not need to be accurate to the millimetre — the factory will draft a production pattern from the spec and the measurements, not from a scaled drawing.
Can AJSAMCO help develop a tech pack?
Yes. We work with brands at all stages of product development. If you have a reference garment and a clear idea of what you want to change, we can develop a production spec from that reference alongside the sample. Send us your reference product, describe what you want to change, and we will confirm what we need to begin.