It’s been a wild ride lately in the manufacturing world. Whether you're producing locally or sending work overseas, it seems like there’s always something going wrong- tariffs going up, delays at customs, or just plain poor communication. Yep, it’s exhausting.
I’m not going to list tariffs here (they’ll probably change again before you even finish reading), but I am going to talk about something that gives you back control: onshoring.
Onshoring, or bringing your manufacturing closer to home, isn’t just a buzzword. It’s becoming a real game-changer. Whether you're already making things in-house or you're totally new to the idea, I’ll walk you through how to start, what to think about, and why it might just be the best decision you make this year.
What Is Onshoring and Why Does It Matter?
Let’s start with the basics. Onshoring is when you move your production from offshore factories (usually in another country) to somewhere closer—often right here in Australia. Some people call it “reshoring” or “local production,” but it all means the same thing: making stuff closer to home.
Now, I get it. Overseas production looks cheap on paper. But as many people I work with quickly find out, the “real” cost is often hidden in rework, delays, freight, and communication headaches. That’s why we’ve been running a masterclass called The True Cost of Offshore v Onshore since 2018—and every time, people walk away shocked at how different the full picture really is.
Onshoring Means More Control, Less Guesswork
Here’s the truth: the more steps you control, the less stress you feel. That’s why I’ve broken it down into five easy stages so you can dip your toe into onshoring at your own pace.
Stage 1: Let Someone Else Do It All (But Know the Risks)
This is where many start—just sending everything offshore. You provide a tech pack, they do the rest. But if your factory closes down, changes staff, or disappears (yep, it happens!), you’re stuck. You don’t own your patterns, your fit, or even your product. You’re vulnerable.
Stage 2: Own Your Patterns
This is your first step toward flexible, resilient production. When you own your patterns—created professionally and graded correctly—you’re not locked into one factory. You can move your production from offshore to local without losing fit or quality. Want to split production across two countries? Easy. Need to respond quickly to a small local order? Done.
Stage 3: Keep Your Graphic Files on Hand
At this stage, you or your team create the graphic files and keep them on file. You’re still producing offshore, but you now have what you need to trial local manufacturing too. This is where onshoring gets real. You might use offshore for big runs, but whip up a smaller order locally when timelines are tight. It’s all about flexibility.
How to Make Onshoring Work for You
Once you get a taste for onshoring, you might want to take it further. Here's how.
Stage 4: Start Bringing Steps In-House
Got sewing skills? Maybe you start by sending your graphics to a local printer and cutting/sewing it yourself. Or maybe you buy a printer and send it out for calendar pressing and laser cutting. You don’t have to jump in headfirst—start with one piece of the puzzle.
The best part? You don’t need everything at once. Plenty of people get others to handle parts of the process, which often turns out to be cheaper and faster.
Stage 5: Run the Whole Show—and Help Others
Once you’ve built your local setup, why not offer your services to others still stuck in stage 1, 2, or 3? There’s a huge need for flexible local production, especially in custom sportswear. Onshoring doesn’t just help your business—it opens the door to help others too.
What You’ll Need to Get Started
This will vary depending on where you’re at, but here’s a rough guide:
Stage 3: All you need is a graphics program like Adobe Illustrator. Easy.
Stage 4+:
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Sewing: You’ll want a 4-thread overlocker and twin needle cover stitch machine to start. Add a straight stitch if you're making polos. We love and buy Juki Sewing machines.
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Printing: Talk to companies like Epson or Mimaki (we love them both!) and see what suits your needs.
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Shows to Visit:
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Europe? FESPA Berlin, 5–9 May—I’ve just been there! You will get the chance to talk to everyone in printing, fabric, ink and paper.
It looks like next year is in Barcelona so add this to your diary. 19th-22nd May 2026 -
Australia? PacPrint is happening at the end of May. Pattern Room will be at the Mimaki stand. Come see how simple this process really is.
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USA? You’re spoiled for choice. We partnered with Millcraft at Impressions this year and loved the energy.
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What About Fabric?
Great question—and one I get all the time. Depending on where you’re based, I’ve got fabric contacts around the world and am happy to share. Reply to this email and I can help you find a fabric partner to work with.
Is Onshoring Really Cheaper?
It might not look cheaper at first glance. But when you factor in:
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Quality issues
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Airfreight on urgent resends
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Long lead times
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Missed sales
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Staff waiting around for late deliveries...
...onshoring starts to look like a no-brainer.
Plus, let’s be honest—having your factory down the road is a lot easier to deal with than one across the globe in a different time zone.
Real Talk: Onshoring Is the Smart Path Forward
If you’ve ever said, “I’m over the headaches,” then onshoring might just be your answer. You don’t have to go all-in from day one. Take it step by step. Try a local print run. Make a few pieces yourself. See what works.
You might just find the flexibility, quality, and peace of mind you’ve been chasing.
Ready to Give Onshoring a Go?
If you’re curious about what onshoring could look like for your business, reach out. I’m always happy to chat through your options. Whether you're just starting out or ready to scale up, there’s a version of this that will work for you.
Let’s get you more control, better fit, and less stress. Because when your garments fit perfectly and show up on time? Everyone wins.
