The Concept

Our client, Jared, wanted to develop a polo that combined golf-appropriate style with the practical needs of contractors who require additional length and coverage during movement. The idea centered on a dual-layer construction. The outer layer would provide the appearance and comfort of a traditional polo, while an extended inner layer could be tucked securely into the wearer’s pants or shorts.

The Design Challenge

Traditional polos can pull upward or become untucked when the wearer bends, reaches, or moves throughout the day. The Tuck Down design needed to provide dependable coverage without changing the polished appearance of the outer shirt. The two layers also needed to work together without creating unnecessary bulk, restricting movement, or compromising comfort.

Our Approach

Utah Contract Sewing worked closely with Jared through a series of design sessions to define the product’s fit, proportions, construction, and intended function. We translated the original idea into a practical apparel design that integrated the extended inner layer with a clean, golf-ready outer polo.

Prototype Development

UCS developed and refined a working prototype to evaluate the shirt’s fit, construction, comfort, appearance, and dual-layer functionality. The prototype process allowed the team to refine how the inner layer remained tucked during movement while preserving the look and feel of a traditional polo on the outside.

Material and Component Sourcing

UCS sourced appropriate fabrics and notions for the product based on comfort, performance, appearance, durability, and manufacturing requirements. The selected materials supported the intended combination of professional styling, mobility, coverage, and everyday wear.

Tech Pack Development

After refining the design and prototype, UCS prepared a comprehensive tech pack documenting the product’s measurements, materials, components, construction details, and manufacturing specifications. This documentation gave the manufacturing partner a clear reference for producing the garment consistently.

Manufacturing

UCS worked closely with one of our manufacturing partners in Vietnam to communicate the design, review production details, and execute the manufacturing run. Our team helped carry the product from its initial concept through development, technical documentation, sourcing, and manufacturing coordination.

The Result

The completed Tuck Down polos successfully combined a clean, golf-appropriate appearance with the practical benefits of the integrated inner layer. The resulting garments turned out beautifully and established a polished, functional product ready for use by the Tuck Down brand and its customers.