Plus size bra manufacturer · Extended sizing to 44G

Plus Size Bra Manufacturer: Extended Sizing, Structured Support & Full Cups

KnitUnderwear is a bra factory in Shuyang, making underwear since 2011. We manufacture plus size bras with extended grading across every band from 30 to 44 and every cup from A to G, with 46 and 48 bands as an OEM order. Full-cup, full-coverage and minimiser styles with reinforced channelling and wider side wings for support across the full size run. MOQ 50 pcs per style per colour.

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At a glance

Band sizes30 – 44
Cup sizesA – G
CombinationsEvery band × every cup
Beyond 44 bandOEM: 46 and 48
Garment sizesto US 3XL
MOQ50 pcs / style / colour
Sample time7–10 days
GradingIn-house CAD
Payment30% deposit, 70% after inspection
Band elastic recoveryWash-tested before cutting
Team150 staff, 92 on the sewing floor
Founded2011

What plus-size construction means

Plus-size construction needs re-drafted blocks and different structural engineering.

01

Re-drafted cup blocks

Projection, apex position and cup depth are re-drafted from dedicated plus-size fit forms for each size range.

02

Structural support engineering

Wider side wings with boning channels or power-net reinforcement. Heavier-gauge elastic on the under-band. Wider-set straps for better weight distribution. All engineered per size group.

03

Extended size run QC

Each size in the run is measured against a full graded spec sheet. Measurements are recorded in the QC report for every bulk order.

Plus Size Bra Manufacturer 3Styles Flatlay

Style Range

Full Cup, Minimiser & Soft-Cup Plus

Three silhouettes designed for D–G cups. Wider band and strap proportions for true full-coverage support.

Who Orders Plus-Size Bras From Us

Three buyer types, one factory. MOQ stays at 50 pcs per style regardless of which category fits you.

Inclusive lingerie brands

Building a size-inclusive range from the start

Launching with D–G cups and 28–44 bands as the core range, not an afterthought. Patterns graded from dedicated plus-size fit forms. Elastic recovery and underband hold tested across the full size run before bulk.

Typical order: 50–300 pcs · full cup or minimiser · 3–6 colourways

Brands extending their size run

Adding D+ cups to an existing lingerie line

You already supply XS–XL or 32A–38C and need to add 38D–44G without changing your existing label spec or packaging. We grade the extension from a dedicated plus-size block, not by scaling your current patterns. Elastic batch matched to your existing orders.

Typical order: 50–200 pcs · extension styles only · matching colourways

Adaptive & specialised market

Post-surgical, senior or adaptive lingerie

Wireless soft-cup construction with front-fastening options, mastectomy pockets, or wider comfort straps. Cup range B–F. Engineering prioritises ease of dressing and all-day wear comfort over silhouette. NDA available before spec review.

Typical order: 50–150 pcs · wireless or soft-cup · 2–3 colourways

Which plus-size bra style are you developing?

Each style has different cup construction, support engineering and grading requirements. Knowing your category early means the first sample lands closer to what you need.

Full coverage

Full Cup

Three-part or seamed cup construction with full enclosure up to the neckline. The primary plus-size style for DD – G cups. Apex position and cup projection are re-drafted per size group on dedicated plus-size fit forms.

Cup range: C to G standard · Wire: Optional
Best for: Everyday, basics range, anchor style

Silhouette-reducing

Minimiser

Redistributes cup volume laterally to reduce bust projection under clothing. Full coverage neckline, wider side wing. A technically demanding cup geometry. The reduction ratio must be graded independently at each cup size to stay proportional across the run.

Cup range: D to G · Wire: Usually wired
Best for: Workwear, occasionwear, smooth-under-clothing range

Everyday comfort

Wireless Full Coverage

Wide, reinforced underband carries the support load instead of underwire. Padded or softcup construction, full coverage neckline, stretch side wings. Works well in softer knit fabrics (microfibre, jersey, modal) for a comfortable all-day wear position without wire pressure.

Cup range: B to F · Wire: None
Best for: Loungewear crossover, comfort-first range, sleepwear brand

Accessibility & function

Front-Closure & Adaptive

Centre-front hook-and-eye or clip closure. No reaching behind to fasten. Suited to older customers, post-surgery styles and customers with limited shoulder mobility. Can be combined with full-cup or wireless construction. The closure must be graded to stay centred and flat across the full band range.

Cup range: B to F · Wire: Optional
Best for: Adaptive range, post-surgical, senior market

Extended Size Range — How Construction Changes by Tier

All patterns graded in-house from dedicated plus-size fit forms — not scaled from straight-size blocks. Confirm your full size run when enquiring; grading feasibility is confirmed before sampling.

Size tier Band Cup Key construction changes at this tier
Standard extended 28 – 38 D – G Plus-size cup block; wider strap set; power-net side wings; standard elastic gauge
Mid-plus 40 – 44 D – G Heavier-gauge elastic underband; boning channels in side wing; wider padded straps; reinforced hook-and-eye
Full plus 46 – 52+ D – H Separate graded base block; full encapsulation for F–H; multi-position strap; reinforced frame; quoted per style

Encapsulation styles available to 44F as standard. 46+ and H cup graded separately — confirm range on enquiry.

What to put on a plus-size bra tech pack

Plus-size fit is decided by the size run and the support structure, so these need to be on the sheet before the first sample. A reference bra or photo is enough to start.

1. Size run

Band range and cup range, how cups progress by band, and which sister sizes you want to carry.

2. Fit reference

A fit model or a base size, plus any existing size chart you want us to match.

3. Cup style

Full cup, full coverage, minimiser or other, and the coverage and neckline height.

4. Support structure

Side wing width, boning or power-net reinforcement, and wire or wireless.

5. Band and straps

Band elastic width and hook rows, strap width and whether straps are padded.

6. Fabric and stretch

Fibre content or swatch, stretch direction, and lining for the cup and wings.

Beyond a 44 band? See the FAQ below. Nursing styles are on the nursing bra page, everyday constructions on bra manufacturer, and OEM vs ODM explains which development route fits you.

Support Features

Wide Straps & Multi-Hook Backs

3–4 column hook-and-eye on all sizes 40+. Cushioned strap option and padded underwire channel.

Plus Size Bra Manufacturer Hook Detail

Choosing a support structure for your size run

In plus-size bras, support engineering is decided at the pattern stage. These three structures cover the main options.

Underwired support

Underwired + Power-Net Side Wings

The standard construction for DD – G full-cup and minimiser styles. Steel or resin underwire lifts and separates. Power-net side wings (wider than straight-size) reinforce the band against lateral stretch. Boning channels hold the wing structure flat across sizes 38 – 44.

Typical styles: Full cup, minimiser
Cup range: DD to G standard
Wire: Steel or resin; specify gauge and length in tech pack

Distributed load

Wide Underband + Padded Straps

No underwire: support comes from a wider, heavier-gauge elastic underband and padded straps that distribute weight across a larger shoulder area. The band carries much of the support load. Works well for wireless full-coverage and everyday styles in softer fabrics. Elastic recovery is wash-tested before cutting on every bulk run.

Typical styles: Wireless full coverage, lounge, comfort
Cup range: B to F
Strap width: Usually 20 – 28 mm padded

Structured silhouette

Boning Channel Reinforcement

Spiral or flat boning sewn into channels in the side wings and back panel. Keeps the bra body from rolling or twisting under a larger torso. Used in strapless plus-size styles where the entire support load falls on the band, and in longline bras where the extended body must stay flat. Boning gauge and stiffness are specified per size group.

Typical styles: Strapless, longline, bustier
Cup range: C to G
Boning: Spiral steel (strapless) or flat resin (longline)

How we keep plus-size bra bulk the same as your sample

In plus-size bras the usual complaint is a band that stretches out and loses support. It is invisible at inspection, so we treat it as a separate step.

1

Grading is done in-house

Patterns are graded on our own CAD system, so the size run is built from one base pattern instead of being passed between workshops.

2

Recovery is tested before we cut

Elastic recovery is wash-tested on the production fabric. The report goes to you before cutting starts. AQL inspection at the end checks visible defects.

3

Same batch as your sample

Band elastic comes from a designated supplier and the spec sheet ships with your goods. The elastic in your sample and in your bulk order comes from the same batch and dye lot.

Payment follows inspection: 30% deposit to start production, 70% balance after you approve inspection. How we run QC →

Private Label Finishing — Included in Every Order

Woven labels, hangtags and polybags are sourced and attached at our factory — no third-party finisher required.

Woven & care labels

Brand size label, care/content label and country-of-origin label stitched in during assembly — not added loose after production.

Printed hangtags

Custom card printed, hole-punched and attached before packing. Supply a print-ready PDF or we apply a standard template at no extra charge.

Per-piece polybag

Clear polybag with header card, or printed branded polybag. Each piece bagged individually and size-sorted before carton packing.

Gift box / set packaging

Rigid gift box or branded set box from 200 pcs per style. Suited for bra-and-brief sets, gift bundles and inclusive range launch collections.

From First Contact to Bulk Delivery

Five steps, two milestones you control — quote approval and sample sign-off. Grading feasibility is confirmed before sampling starts.

1

Get a Quote

Send your target size run, construction type and reference. We confirm grading feasibility and reply with a base FOB price within 48 hours.

2

Confirm Spec

Lock in cup construction, support structure, fabric, size run, label and packaging. We issue a graded spec sheet for sign-off before cutting.

3

Sample — 10–14 days

Sample made in your base size and shipped. Underband elastic recovery tested before dispatch. One free revision included.

4

Approve & Order

Sign off the sample and place the bulk PO. 30% deposit starts production; sample fee credited back against your order.

5

Bulk — 30–45 days

Full size run produced, elastic recovery wash-tested across size tiers, AQL inspected, then FOB Shanghai or Ningbo. Full inspection and grading report included.

Frequently Asked Questions

Can you grade a plus-size bra up to 46 or 48 band?

Our standard range goes to 44 band and G cup. Grading beyond 44 band requires re-fitting at the extended sizes, which adds to sample cost and time. We can do it as an OEM order with a dedicated fitting session. Email us to discuss your size run and we will advise on feasibility.

Do you use the same patterns for plus-size as straight-size?

No. Plus-size styles are drafted on dedicated plus-size fit forms. A straight-size pattern scaled up to a 44G will not fit correctly: cup projection, apex angle and under-band curve all need adjustment. Our CAD team does this as part of the standard pattern-making process for any plus-size OEM order.

What size range do you cover for plus-size bras?

Every band from 30 to 44 in every cup from A to G is standard, with garment sizes up to US 3XL. Bands 46 and 48 are handled as an OEM order with a dedicated fitting session.

What is your MOQ for plus-size bras?

50 pieces per style per colour, with sizes mixed freely across the run.

How long do samples and bulk production take?

ODM samples take 7 to 10 days and new OEM patterns 10 to 14 days. Bulk production takes 30 to 45 days from sample sign-off.

How do I know bulk will match my approved sample?

Patterns are graded in-house on our own CAD system. Elastic recovery is wash-tested on the production fabric and you receive the report before cutting. Band elastic comes from a designated supplier, the spec sheet ships with your goods, and sample and bulk use elastic from the same batch and dye lot.

How does payment work?

30% deposit to start production. The 70% balance is due after you approve inspection.

Do you sign NDAs?

Yes. We sign an NDA before spec review, and your design is not shown to other buyers.

Do you ship DDP or FOB?

Both. We quote FOB Shanghai or Ningbo, or DDP delivered to your door, whichever suits your import set-up.

Can I order matching plus-size bra and panty sets in the same production run?

Yes. We manufacture plus-size bras and bottoms in the same facility, so a matching set order runs together. Fabric and colourway are confirmed from one dye lot to keep the pieces consistent. MOQ applies per style and colour (50 pcs for the bra style and 50 pcs for the matching bottom) and both ship in the same bulk order. If you are building a full lingerie range with coordinating pieces, include the complete style list in your enquiry and we will quote everything together.

What cup sizes can you manufacture in plus sizes?

We manufacture up to a K cup in plus-size constructions. Standard range is D through G; extended cups H, J and K are available in seamed styles and select full-coverage moulded styles. Cup depth and wire length are graded separately from the band, so larger cups maintain proportion rather than simply scaling up. If you need a specific cup-to-band combination outside our standard range, send the measurement spec and we will confirm feasibility at the quoting stage.

What plus-size bra styles are available?

Full-coverage, balconette, plunge, minimiser and front-closure styles are all available in our plus-size blocks (bands 36–48, cups D–K). T-shirt moulded styles are available up to a G cup; larger cups use seamed construction for better shaping and support. Wireless styles (soft-cup and bralette) grade up to a 2XL/3XL frame. Sports bra styles with encapsulation are available up to a 44F. Send your target size range and we will confirm which blocks fit your brief.

What Plus-Size Brands Say

Size grading done in-house. Two brands that fixed their fit.

“

Our old supplier’s size chart didn’t fit North American customers. KnitUnderwear regraded all sizes for our lingerie line, and our return rate dropped sharply.

Elara Studio

USA · Plus-size everyday lingerie · Sizing grading optimisation

Size grading

“

Stretch consistency was critical for our plus-size lingerie. Bulk goods passed stretch testing and matched our pre-approved sample perfectly.

Maya · Curva Studio

USA · Plus-size everyday lingerie · Stretch performance & sample-bulk alignment

Stretch consistency
Quote Request

Get a free quote in 24 hours

  • ✓  Low MOQ — from 50 pcs per style / colour
  • ✓  OEKO-TEX® Standard 100 & GRS 4.0 certified fabrics available on request
  • ✓  Full OEM / ODM & Private Label — your design, labels & packaging
  • ✓  DDP worldwide shipping — door to door, duty included
  • ✓  We reply with pricing usually within one business day
120+
Brands served
32
Countries shipped to
200+
Base patterns on file
7–10
Days to first sample

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📱  WhatsApp: +86 189 5124 3330

✉  Email: abby@knitunderwear.com