Removable Pad Sourcing and Insertion Methods
Removable pads are treated as an accessory and behave like a component. They drive a disproportionate share of consumer complaints: pads that fold in the wash, pads that migrate to one side, pads that curl at the edge after a few cycles, pads that show through the shell fabric. Every one of those is a specification decision made months earlier. If the pad is not specified with the same rigour as the fabric, the first review mentioning it will arrive after the launch.
Pad Constructions Available
Three constructions dominate. Moulded foam cups are pressed to a three-dimensional shape, hold their form best, and require tooling. Die-cut foam is cut flat from sheet foam, is cheaper and faster, and is flatter in shape. Bonded or laminated pads use a fabric-faced foam with a bonded edge, giving a cleaner look and better wash stability at higher cost.
Typical thickness for a medium impact bra is 5 to 12 millimetres, with density selected to balance shape retention against weight. Heavier is not better; a heavy pad pulls on the pocket and changes how the cup sits.
Insertion Methods
The construction of the pocket matters as much as the pad. An open slit pocket in the side seam of the cup lining is the lowest cost and the most prone to migration. An envelope pocket with a finished opening gives better retention. A snap or hook-and-loop tab fixes the pad in place but adds hardware, an operation and a potential scratch point.
Specify the pocket opening width relative to the pad width, usually 10 to 20 millimetres narrower, and specify the lining fabric. A slippery lining lets the pad travel; a brushed or higher-friction lining holds it. State whether the pocket is accessed from the top or the side, because that changes both the sewing sequence and the consumer experience.
Specifying the Pad
Give shape, thickness with a tolerance of plus or minus 0.5 millimetres, weight, colour, and density. Require colour fastness to washing and perspiration under the ISO 105 series, since a pad that bleeds will stain the shell. Require OEKO-TEX STANDARD 100 certification, and REACH and CPSIA declarations where the destination market demands them.
Confirm the edge finish. A raw cut foam edge will fray and curl; a skived or sealed edge lasts longer and is worth the small premium.
Sourcing and Cost
Sourcing through the garment factory is simpler and is the right answer below about 5,000 units. Sourcing directly from a pad specialist gives better shape control and lower unit cost at scale but adds a supplier to manage and inbound freight to coordinate.
Indicative costs: die-cut pads from about USD 0.30 to 0.60 per pair, moulded pads from about USD 0.60 to 1.30 per pair depending on tooling and volume. Moulded tooling typically costs USD 300 to 1,200 per shape and takes 30 to 45 days. Minimums per shape commonly run 500 to 2,000 pairs.
Failure Modes to Test
Before approving bulk, run the finished garment through a domestic washing procedure such as AATCC 135 or the ISO 6330 equivalent for at least five cycles with the pads left in place, then inspect. Look for edge curl, folding, migration out of the pocket, and any visible ridge through the shell fabric.
Also test pad insertion and removal by hand at least ten times. A pocket that is too tight will tear at the seam in consumer use, and that is a returns problem that no inspection will catch.
