Chapter 4 : Manufactures

After the idea, the testing, and the tweaking comes the manufacturing phase—the magical moment when your product finally takes shape!

My original plan was simple: contact a manufacturer, ask for the cost to produce one bodysuit along with their minimum order quantity, and then calculate my selling price. (Quick tip: Selling prices are usually about 2.5-3 times the production cost to cover logistics, marketing, salaries, etc.) This would give me a clear idea of my initial investment and also I would be able to define my selling price. Little did I know, it wouldn't be that straightforward!

To nail down production costs, the manufacturer needed details like the time it takes to sew each piece and the cost of all the materials (fabric, snap buttons, and so on). So, I had to dive into the prototyping process before I could even get a solid estimate.

My first thought was to work with a Portuguese manufacturer because of the close proximity. I reached out to a small brand I admired—they made their clothes in Portugal. Although they didn't reveal which manufacturer they used, they advised me to do my homework: search online, read reviews, and even visit the facility to see if I felt comfortable working with them. One quirk about Portugal, though, is that you must already have a company set up; otherwise, they won't even consider making a prototype. Fortunately, I was able to leverage my mom's company for this purpose.

I compiled a list from the internet, read reviews, and emailed around ten different manufacturers. Most of them turned me down because they either didn't have the resources, weren't interested since I was a small player, or simply didn't produce baby clothes. After several exchanges, one small manufacturer finally agreed to create a prototype. I sent them a sample I'd made myself, along with all the modifications I wanted (sizes, fabric, etc.). We hashed out details via email and even had a video call, which was awesome—you get to see the people you're "hiring". I even organized a short trip with a friend to visit the facility. Honestly, I could have skipped the visit—it was super brief (five minutes visiting the facility and a 15-minute chat and €120 taxi drive). For prototypes, sometimes a visit isn't really worth it.

As mentioned in Chapter 3, I paid €170 for the prototype, delivery included. With that sample in hand, I tested it on my daughter and noted the tweaks needed. Then came the production cost, and my faith started to waver. The numbers were so high that my selling price would need to be at least €60 for a bodysuit (plus an extra bottom piece). Sure, people pay that much—or more—for baby clothes, but consider this: a bodysuit is something you change often (so you need several), and it's a one-person deal because stains are inevitable. A €60 price tag meant only the well-heeled would be interested, and those customers might have help from babysitters. My target buyer? A middle-class, working mom just like me. €60 was simply too steep.

After that low moment, I decided to expand my search beyond Portugal. Next stop: Indonesia, where a friend mentioned I might find more attractive production costs. I repeated the process—emailing a list of manufacturers (this time ensuring they actually produced children's clothing). I eventually found one willing to work with me and arranged a video call. They explained that, like in Portugal, they'd need to create a prototype to estimate production costs. The twist? I didn't need an established company to work with them. Instead, they required a "tech pack"—a detailed document outlining the product's technical design, materials, and specifications. I sent them photos of my prototype along with every detail about the bodysuit, fabric, and colors I wanted.

An extract of the tech-pack

After some back-and-forth via email (thankfully, no Bali trip was needed—my funds would have taken a hit before the business even started), they produced a tech pack. Once I approved it (after a few tweaks), they went ahead with the prototype. The entire process—tech pack, sample production, and shipping—cost me $384. The bad news? When I asked for a confirmed production cost and the minimum order quantity, they said the only way to know the exact price was by proceeding with bulk production. Their ballpark estimate was $25-$35 for the top and bottom set. I was really disappointed because I had been crystal clear from the beginning: I needed to know production costs before committing to a large order (since I was still growing my audience). Lesson learned! On the plus side, I now had a tech pack I could show to other manufacturers. Ultimately, I decided not to pursue the Indonesian option because, in the end, their prices were even higher than Portugal's—or maybe they just wanted to get rid of me!

So, I cast a wider net—searching in Vietnam, Lithuania, the Philippines, and beyond—until I finally landed on India. I found an Indian manufacturer who offered production prices that would let me sell the bodysuit at an affordable price for my badass moms. I can't spill too many details yet since it's a recent development, but they're currently working on a sample to see if the quality and design meet my expectations. I'm also asking friends if they know anyone in India or are planning a trip there, so they can visit the factory and give me a firsthand impression of the working conditions and management. I have no qualms about working in India—I love that country (I've been there before)—but I want to ensure the workers are respected and the products are top-notch.

Looking ahead, I plan to work with European manufacturers once my production volumes increase and prices become more competitive. I'll keep you posted on my journey (maybe it's time to plan another trip to India).

Until the next chapter, sending you lots of love,

The badass mom behind wearfunbaby.