Garment defects in fashion can be stains, holes, distortions, shrinkage, and more. They’re annoying for end customers, and they can increase returns and decrease brand loyalty.

So, what are the most common fabric defects in garments, their causes, and how do you prevent them during bulk production?

Most Common Fabric Defects in Garments and Their Causes (with photos)

These are the 7 most common fabric defects and their causes:

• Fabric stains
• Uneven fabric color
• Color bleeding
• Fabric shrinkage
• Holes, snags, and runs
• Fabric distortions
• Fabric yarn defects

Fabric stains 

Blemishes such as oil spills, food stains, or ink marks will disappoint customers. (I know it seems crazy, but yes, blemished fabric can make its way through the production line, sometimes after bulk production is done.)

Common causes of fabric stains: mishandling during sewing, transportation, or storage

Uneven fabric color

This one is tricky to spot! Uneven color in garments manifests through mismatch shades on certain areas of the clothing. 

Imagine your sleeve piece being shades off from your body piece. Unless you’re (intentionally) color-blocking, that’s not a great look!

Common causes of uneven fabric color: errors during the dyeing process, exposure to sun, improper storage

Color bleeding

Ever washed your colored clothes together and they all ended up red? This fabric defect is one of the most common headaches for fashion designers and customers. 

Common causes of color bleeding: use of low-quality dyes, incorrect dyeing processes, fabric used does not absorb color well

Fabric shrinkage

Fabric shrinkage is one of the most annoying fabric defects in garments. This happens when the fibers contract due to exposure like heat or moisture during laundry.

I imagine you know the pain of purchasing a well-fitted garment only to have it shrink into a completely different size after the first wash. We don’t want your t-shirts turning intro crop tops.

Common causes of fabric shrinkage: inadequate fabric pre-treatment, improper care instructions regarding washing and drying

Holes, snags, and runs

These issues often arise in more sensitive fabrics like silk, nylon, and rayon. They not only compromise the overall quality of the garment but also require careful handling to avoid further damage. 

Common causes of holes, snags, and runs: improper handling and storage, poor quality yarns, manufacturing defects

Fabric distortions

Fabric distortions come in different forms such as skewing, bowing, and warping. These distortions might not seem like a big deal from afar, but ultimately affect the quality and fit of your garments. (Ever had a t-shirt or pants that look fine but over time sort of started twisting around your waist or leg? That’s fabric distortion!)

Common causes of fabric distortions: lack of pre-treatment, improper handling during yarn/fabric production, excessive loom weaving machine tension

Fabric yarn defects

Seen through missing or broken yarns, faulty yarns, uneven yarn size, knots – fabric yarn defects directly affect fabric quality and can cause weakened areas, compromising its overall integrity and durability.

Common causes of fabric yarn defects: flaws in yarn production, incorrect tension while weaving, use of low quality materials  

How to Troubleshoot And Prevent Fabric Defects in Garments

The only way to prevent these defects is to be eagle-eyed when checking samples or evaluating stock fabrics that you may be buying. You also need to clearly communicate these findings to your manufacturers. 

While fabric defects might appear isolated in samples or on a swatch card, you don’t want them to affect the entire fabric lot. That means disasters during bulk production. 

So, here’s exactly how to troubleshoot and prevent.

1. Inspect garment samples for fabric defects

When you get the sample, take a good look at it inside and out. Make sure that you do your inspection under optimal lighting conditions so you won’t miss any details.

Inspect the garment not only up close but also as a whole. Remember the uneven fabric color defect we talked about earlier? This is one good way to catch it! I even like to take garments outside in the natural sun or put it on a friend or coworker so I can step back and look at it from a distance.

2. Call-out fabric defects in your sample evaluation form 

Mark all fabric defect concerns in your sample evaluation notes and include a clear explanation and photos. This is how I like to do it – it takes a little more work, but will ensure your manufacturer sees and knows what you’re referencing. 👇

Pro tip: Use stickers or tape to mark fabric defects on your physical samples. If possible, you can send back these marked samples to your manufacturer so they have a physical guide of what to look out for. 

3. Implement quality control measures 

When working with outsourced manufacturers, there are several essential quality control measures you can implement. 

Bigger fashion brands usually hire a third-party quality control service or inspection agency to visit the manufacturing facility on their behalf. These services conduct random checks on fabrics and finished garments, ensuring they meet your specified standards. 

But for start-up fashion brands, you don’t have to outsource. Most manufacturers actually have their own quality control teams, so talk to them about what measures they implement for QC.

To be extra sure, you can request fabric testing for crucial points like colorfastness, shrinkage, and strength. These tests help identify potential fabric defects during production or after garment care.

If you want to go the extra mile, simple versions of these tests can also be done at home. When I was working as a remote freelance fashion designer, I conducted some of the wash testing myself. 

Request two copies of one size from your manufacturer or measure the sample beforehand. Then, follow the recommended washing procedure and check for any differences in measurements. For an added assurance, toss a white piece of cloth into the wash to see if it gets stained by the sample’s color, testing for bleeding.

P.S. I have a more thorough guide on how quality control works in the fashion industry. I explain the processes I just mentioned above in more detail in this guide.

4. Work with reputable factories and suppliers in the apparel industry

Manufacturers often source their fabrics from various suppliers. Make sure they are partnering with reliable and reputable suppliers to ensure consistent fabric quality.

Pro tip: Ask the manufacturer to keep fabric swatches from each production batch, and also keep your own copy in hand. By having fabric swatches on hand, you can cross-check the fabric quality if any issues arise after the garments are shipped.

Fabric Quality Is More Than Just Aesthetics

The fabric you use for your garments determines how it will fit, feel against the skin, and stand the test of time. High-quality fabrics make garments more special, warrant higher prices, and can increase repeat customers.

Have you ever owned a pair of Lululemon leggings? I have about 7 pairs. Many of them are 5+ years old, have been through plenty of hot yoga classes, hikes, and more. I also wash and dry them all. (Even though you’re not supposed to.) And allllllll of the fabric on those leggings looks and feels like it did when they were brand new. No pilling, no snags, no distortion.

Contrast that to a pair of inexpensive leggings from Target or Amazon. I have had a few of those as well. Within a year, the fabric in the crotch is all pilled, and there are snags on the thighs.

So, I pretty much only buy expensive leggings that are made from great fabric from brands I trust… because I know they’ll last forever.

Arguably, these are not fabric defects. But it goes to show how a brand’s reputation is on the line and how quality can bring customers back for more.