Why Most Startups Return to Local Clothing Manufacturers After Going Offshore

Why Most Startups Return to Local Clothing Manufacturers After Going Offshore

If I had a dollar for every early-stage founder who moved production offshore…

and then came straight back to a local manufacturer after a few months…

I could fund half of WearLab’s operations.

It happens constantly  especially with new brands producing small batches. And it always comes down to the same three issues:

 

1. Communication Becomes the First Roadblock

Offshore manufacturing requires experience.

Not just in production  but in communication styles, technical translation, and the ability to spot issues early.

Most new founders underestimate how hard it is to communicate when:

• There’s a language barrier
• Time zones delay every conversation
• You’re not familiar with offshore development processes
• Tech pack instructions need to be extremely detailed
  

With a local manufacturer, you can speak your own language, jump on a call quickly, drive to the studio, or drop off samples.

Communication becomes faster, clearer, and easier especially during early development.

 

 

2. Timelines Are Not Designed for Small Brands

This is something founders rarely know:

Offshore factories build for 2–3 seasons ahead.

They’re working with big brands. Their lines are booked.

So when a new founder wants a fast turnaround…

But hasn’t planned their launch months in advance…

Or has an MOQ of 50 instead of 5,000…

The factory simply can’t prioritize them.

That’s why production “takes forever to get moving.”

Local manufacturers have shorter lines, faster approvals, and can be more flexible with small batch clothing manufacturing  especially in cities like Vancouver.

 

3. Costs Don’t Make Sense Once You Add Everything Up

Yes, offshore looks cheaper on paper.

But new founders don’t factor in:

• Shipping (which can cost more than the product)
• Duty fees
• Corrections and remake fees
• Long sampling timelines
• Delays from incomplete tech packs
• Minimum order quantities much larger than they need
  

At the startup level, those unexpected costs can easily wipe out the supposed “savings.”

This is why so many founders tell me:

“Offshore ended up being way more expensive than I thought.”

 

So Should Startups Avoid Offshore Completely?

Not necessarily.

Here’s the simplest way to think about it:

Startups with low MOQ, limited experience, and short timelines → Start Local

You’ll learn faster.

Communicate easier.

Minimize risk.

Build real relationships.

This is where small batch clothing manufacturers in Canada shine.

Brands with experience, strong budgets, and clear technical requirements → Go Offshore

Or work with someone who already has a vetted offshore network.

Offshore works great  when you know exactly what you’re doing.

 

My Honest Opinion After Working With Hundreds of Startups

If you’re a new founder doing everything yourself:

Start local.

Once you grow  move offshore strategically.

If you want to go big from Day 1 and your pieces are complex:

Work with someone who already has the relationships and understands offshore production.

But jumping offshore alone, without knowledge, without experience, and with small MOQ. Almost always circles right back to where you started:

Local manufacturing.