Thermal Cycling Jersey Manufacturer: Brushed-Back Race Jerseys Fitted and Measured Against Your Summer Jersey
We develop the thermal cycling jersey as the cool-weather version of your race jersey: a long sleeve race jersey in brushed-back thermal main body, drafted on the same riding-position block as the summer jersey in your project and worn as the jersey itself.
We develop it for product leads at performance cycling brands adding a cool-weather line to a race range, technical leads at race teams and club race squads who race spring and autumn and train through winter, and technical directors at cycling federations dressing several squads for a full season.
The thermal jersey gets its own sample, its own on-bike check and its own fit signature, even when your summer jersey is already signed. Its measurement report lists back length, sleeve length and chest next to the same size of your summer jersey, so you can read size by size that the two garments match before anything is produced.
Send us your size chart and your summer jersey spec pack, and we reply with a thermal jersey development plan.
What you receive with every thermal jersey:
- A separate sample and a separate fit signature from the pattern maker.
- Back length, sleeve length and chest measured side by side with the same size of your summer jersey.
- An eight-part spec pack, with all files and the revision log owned by you.
- A first sample in 5–7 days, and up to 2 revision rounds with no extra sampling fee.
- Fabrics certified to OEKO-TEX® STANDARD 100.
Thermal Cycling Jersey for the 10–16 °C Band: Spring and Autumn Racing and Winter Training
The thermal cycling jersey is the long sleeve option in the 10–16 °C band of our range. It is a long sleeve cycling jersey in brushed-back thermal main body with no windproof front, so it keeps the close race fit of the summer jersey and gives the rider a brushed inner face against the skin.
Riders wear it for:
- Early-season road races and criteriums held in the 10–16 °C band.
- Autumn races at the end of the calendar.
- Winter training blocks, where a team wants riders in the same fit they race in.
The full set of garments for each temperature band, from the summer jersey to the windproof jacket, is laid out on our race cycling apparel range page.
Tell us the bands your calendar covers, and the feasibility review names the thermal jersey's place in your set.
Thermal Jersey Fit Proven on Its Own Sample, Measured Side by Side With Your Summer Jersey
The thermal jersey starts from the riding-position block of the race fit jersey in your project, with no layering ease added. The block is the starting point. The fit is proven again on the thermal jersey itself, in the brushed-back fabric it will be produced in.
A separate sample.
When your summer jersey is already signed, the thermal jersey is still cut and sewn as its own sample. We do not carry the summer jersey's fit signature over to it.
A measurement report set beside your summer jersey.
The sample technician measures the thermal sample point by point against the same size chart as your summer jersey. In a project that has a summer race jersey, three points are listed side by side with the same size of that jersey:
- Back length.
- Sleeve length.
- Chest.
The sample technician signs the report for size. You read the two columns size by size, or lay the two samples flat and measure the three points yourself with a tape against the report.
A separate on-bike check.
The rider takes the race position in the thermal sample, and the pattern maker runs the same on-bike check used on our race fit cycling jerseys, with the two long sleeve items included:
- The four race fit points: hem, collar, sleeve end and shoulder movement.
- Arms reaching to the hoods, the sleeve covers the wrist.
- In race position, the rider reaches the rear pocket opening with one hand.
Each item is marked pass or return in the fit sign-off column of the thermal jersey's own measurement report. A returned item names the panel it goes back to, such as the sleeve panel for a sleeve that pulls off the wrist, or the back panel for a pocket out of reach. The pattern maker signs the fit when every item passes.
A report that does not pass stops the sample. It is not sent to you. It goes back to the pattern maker, the panel is changed, and the change is written into the revision log with the panel, the change and the reason.
What you hold at the end:
- Two measurement reports in the sample set, one for the summer jersey and one for the thermal jersey, each with its own fit signature.
- The thermal report with back length, sleeve length and chest set beside the summer jersey, size for size.
- The thermal sample itself, so your own riders can repeat the check against the signed items.
The development work behind each report runs under ISO 9001:2015.
Choices That Set Your Thermal Jersey: Fabric by Panel, Zip, Versions and Decoration
A thermal jersey brief settles four choices. Each one lands in a named file of the spec pack.
Fabric by panel.
The pattern maker proposes from your brief which panels are cut in brushed-back thermal main body and which in mid-weight stretch main body. The proposal is a starting point. You confirm it, and the confirmed assignment is written into the fabric-by-panel sheet for every panel.
Front zip.
A full-length or half-length zip changes how the centre front is split into panels. The pattern maker draws the split for the zip you choose on the cutting diagram.
Men's and women's versions.
Each version you ask for gets its own base block, graded to its own size chart. When your summer jersey already has men's and women's blocks, the thermal jersey starts from each of them.
Decoration.
Full sublimation, heat transfer, embroidery, reflective print or reflective strip, and a silicone gripper at the hem. Each position is drawn on the placement sheet, including any reflective detail at the rear pocket opening for training rides in low light.
You can check the fabric-by-panel sheet by hand on the finished sample. Turn the thermal sample inside out and the brushed face shows on every panel cut in the thermal fabric. Hold it against the sheet you signed, panel by panel.
Thermal Jersey Construction by Zone: Panels, Collar, Sleeves, Hem, Pockets and Seams
Each zone of the thermal jersey is drawn on the riding block and marked on its cutting diagram.
Panels.
Every panel carries the base fabric named in the fabric-by-panel sheet you confirmed, brushed-back thermal main body or mid-weight stretch main body. Both are binary nylon-spandex, so the two fabrics join into one garment on one colour standard.
Front and collar.
The front is cut shorter than the back for the race position, and the collar line is dropped at the front so the collar stays off the throat. The thermal jersey keeps this collar line from the riding block, and the gilet in the same project is drafted to sit over it.
Sleeves.
The sleeve head is set at the angle of the arm reaching to the bars. The sleeve runs to the wrist for arms on the hoods and closes with the same elastic cuff as our race fit long sleeve jersey.
Back and hem.
The back is cut longer to cover the lower back when the rider is low, and the hem carries a silicone gripper drawn on the placement sheet.
Rear pockets.
The pocket line is drawn on the back panel of the riding block, at the height a rider in race position reaches with one hand, and marked on the cutting diagram.
Seams.
Contact zones are joined with flatlock seams, so no raised ridge lies against the skin on the brushed inner face. Main body joins are four-thread overlock. Every seam is listed by type in the seam description.
Layering the Thermal Jersey Under a Gilet and With Leg Warmers
In the 10–16 °C band the thermal jersey is worn as the jersey, a gilet goes over it on days that need a windproof chest, and leg warmers complete the set. We develop the three to fit together.
The thermal jersey carries no layering ease. It is cut close, on the riding block, so it sits under a gilet the way the summer jersey does.
The gilet in the same project is drafted on that same riding block, with layering ease added by the pattern maker against your brief and drawn on the gilet's own cutting diagram.
Two places decide whether the pair layers cleanly:
- Collar. The thermal jersey keeps the dropped front collar line of the riding block. The gilet collar sits over it, with the gilet's ease drawn on its own cutting diagram.
- Armholes. The gilet armhole sits over the thermal jersey's sleeve head, so the rider reaches to the bars through both layers.
The layering check is done in the gilet's fit session:
- The gilet sample is put on over the thermal jersey sample from the same project.
- The rider takes the race position on the bike.
- The four on-bike points are checked again through both layers.
- Each point is marked pass or return in the fit sign-off column of the gilet's measurement report, and the pattern maker signs it.
A returned point names the gilet panel it goes back to, and the change is logged before the next gilet sample. The thermal jersey's own fit signature stays as it was.
Leg warmers are graded to the size chart you confirm, independently of the jersey, with a silicone gripper band at the top opening. Developed in brushed-back thermal, they are matched to the same colour card as the thermal jersey.
What you hold at the end:
- The thermal jersey report, with its own fit signature.
- The gilet report, with a fit sign-off completed over the thermal jersey sample.
- The leg warmer report against your size chart.
- All three samples in the sample set, so your riders can try the full 10–16 °C set before production.
Outer layers are covered on our cycling gilet manufacturer page and our cycling layering system by temperature page.
Thermal Cycling Jersey Specification
| Item | Specification |
|---|---|
| Garment | Long sleeve race jersey in brushed-back thermal main body, worn as the jersey |
| Temperature band | 10–16 °C, the long sleeve option of the band |
| Pattern | Riding-position block of the race fit jersey in your project, no layering ease |
| Fabric by panel | Brushed-back thermal main body and mid-weight stretch main body, panel assignment proposed by the pattern maker and confirmed by you |
| Fabric blend | Binary nylon-spandex in 88/12, 90/10 or 91/9; the brushed back is a finishing variant of the same blend |
| Fabric certification | OEKO-TEX® STANDARD 100 |
| Seams | Flatlock in contact zones, four-thread overlock on main body joins |
| Decoration | Full sublimation, heat transfer, embroidery, reflective print or strip, silicone gripper hem |
| Sizing | Graded to your size chart and size range; men's and women's versions on separate base blocks |
| Fit check | Four race fit points, sleeve covering the wrist on the hoods, one-hand reach to the rear pocket |
| Measurement | Against your size chart; back length, sleeve length and chest beside the same size of your summer jersey |
| Colour | Strike-off on the brushed-back fabric under D65, signed colour card |
| Development | First sample in 5–7 days; first 2 revision rounds with no extra sampling fee |
| Deliverables | Thermal jersey files in the eight-part spec pack, sample in the sample set, revision log |
The brushed-back thermal main body is a finishing variant of our binary blends, not a new blend, so it prints and matches to your colour standard the same way as the summer fabrics in your set. Fabric detail is covered on our race cycling jersey fabrics page.
Send Your Summer Jersey Spec Pack and Size Chart
Send the spec pack or size chart of the summer jersey you race in. Within 48 hours of a complete brief, the development manager replies with the thermal jersey plan: the block it starts from, the fabric-by-panel proposal and the sampling dates.
Thermal Jersey Compared With the Race Fit Long Sleeve Jersey in Main-Body Fabric
Both jerseys are long sleeve race jerseys on the same riding block, and both sit in the 10–16 °C band. They differ in fabric, colour card and how the fit is proven.
Thermal cycling jersey
Race fit long sleeve jersey in main-body fabric
The gilet and the windproof jacket are a different layer: both are worn over a jersey, drafted on its block with layering ease, and both carry a windproof front. The long sleeve race fit jersey and its patterns are covered on our race fit cycling jersey page.
Development Steps for a Thermal Jersey, From Brushed-Back Strike-Off to Signed Sample
The thermal jersey follows our standard development process, with its own strike-off, sample and checks. Each step has an owner and a document you receive.
Brief and feasibility review.
You send the size chart, versions and band, and the summer jersey spec pack if you have one. Within 48 hours of a complete brief, the development manager sends the plan, with the pattern maker's direction.Fabric-by-panel proposal.
The pattern maker names the panels in brushed-back thermal and in mid-weight main body. You confirm the sheet.Strike-off and colour card.
The colour and print technician prints the brushed-back fabric and matches it to your colour standard under D65. You sign the colour card. No sample is cut until the card is signed.First sample in 5–7 days.
The sample technician measures it against your size chart and beside your summer jersey. The pattern maker runs the on-bike check and signs the fit.Revision rounds.
Each round is logged by panel, change and reason. The first 2 rounds carry no extra sampling fee.Spec pack.
The thermal jersey's files go into the spec pack with the full revision log.
Colour Card and Spec Pack Files the Thermal Jersey Adds to Your Project
The brushed-back fabric takes its own strike-off and its own signed colour card. The colour and print technician matches it under D65 to the same colour standard as every other base fabric in your set, and the colour parameters are written into the spec pack. Your summer jersey and thermal jersey come out on one colour standard.
Colour cards count by base fabric, not by garment. A set that already uses brushed-back thermal, for leg warmers or a windproof jacket, already holds that card, and the thermal jersey adds no new one. The full rule is on our race cycling apparel range page.
The thermal jersey adds its own files to the spec pack:
- Cutting diagram.
- Graded pattern.
- Fabric-by-panel sheet.
- Placement sheet.
- Size chart.
- Seam description.
- The thermal sample in the sample set.
Each revision log entry names the garment and the panel changed. Files and revision log are yours at handoff.
Your own line produces from the pack, or the development manager passes it to cyclingapparelfactory.com, our sister site for bulk production. A brand that already holds a summer jersey spec pack from us adds the thermal jersey to the same pack.
Choosing Between the Thermal Jersey, Gilet and Windproof Jacket for Your Brief
Each garment in the cool-weather set has its own role, and we develop each one to that role.
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The thermal jersey is the jersey.
It sits next to the skin, on the riding block with no layering ease, and is graded to the same size chart as your summer jersey, size for size.
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The gilet is the windproof layer for the 10–16 °C band.
When a brief asks for a windproof chest on the thermal jersey, we develop the thermal jersey with a gilet over it.
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The windproof jacket is the garment for the 5–10 °C band, with a brushed-back body and a windproof front, worn over the jersey with layering ease.
The feasibility review names the garment we develop for each line of your brief, so the set covers each band in your calendar. The windproof jacket is covered on our windproof winter cycling jackets page.
Information to Send for a Thermal Jersey Feasibility Review
Send what you have. The more of this list you include, the more specific the review.
- Size chart and size range, and the men's and women's versions you need.
- The temperature bands and race formats in your calendar.
- Your summer jersey spec pack, if we developed it, or the summer jersey's size chart and a reference garment.
- Any panels you want in brushed-back thermal, or leave the proposal to the pattern maker.
- Front zip: full-length or half-length.
- Colour standard and artwork, with decoration and reflective positions.
- Other garments in the set: gilet, leg warmers, windproof jacket.
We reply within 24 hours on working days. If the brief is missing an item, that reply lists what is still needed in one go.
Within 48 hours of a complete brief, the development manager sends the feasibility review:
- Whether the thermal jersey can be developed to your specification.
- The block it starts from and the fabric-by-panel proposal.
- The colour cards the set needs.
- The sampling dates for the first sample.
Related Pages and Our Sister Site
Race fit cycling jersey
the riding block and on-bike check the thermal jersey starts from.
Race cycling apparel range
every garment by temperature band.
Aero cycling jersey development
the short sleeve race jersey for time trials and criteriums.
About us
the development team and who signs each stage.
Home
our development service and process.
Send Your Thermal Jersey Brief
Send your size chart, your calendar bands and your summer jersey spec pack. The development manager replies with the thermal jersey plan, the fabric-by-panel proposal and the dates for a first sample. Request a feasibility review.