What a Bodysuit Actually Costs to Make: $17 to $32
A bodysuit is, structurally, a T-shirt or top extended to the crotch with a snap-close gusset. It uses the exact same jersey knit factory as a T-shirt — but the snap crotch is a genuinely separate CMT operation, and it's almost the entire story of what a bodysuit costs beyond a standard top.
Build A: affordable, China
180 GSM cotton jersey, scoop neck, 3-snap crotch, 300 units:
| Component | Per unit | Notes |
|---|---|---|
| Cotton jersey 180 GSM | $4.40 | |
| Gusset lining fabric | $0.40 | Same cotton jersey |
| CMT — scoop bodysuit affordable mid | $9.00 | Includes snap crotch operation |
| KAM snap set x3 | $0.30 | Heavy-duty plastic, non-negotiable |
| Trims + label | $0.50 | |
| Sampling, QC, buffer, freight, duties | ~$2.83 | combined |
| TOTAL LANDED | $17.43 | |
| Retail (4–5x) | $70–$87 | |
| Gross Margin | ~75–80% |
Build B: premium, Portugal
200 GSM GOTS cotton rib, square neck, metal snap, 150 units:
| Component | Per unit | Notes |
|---|---|---|
| GOTS cotton rib 200 GSM | $9.47 | GOTS x1.23 |
| Gusset lining | $0.70 | Same rib fabric |
| CMT — rib bodysuit premium mid | $15.00 | Includes snap crotch |
| Metal KAM snap x3 (gold) | $0.90 | Premium hardware detail |
| Woven label + hang tag | $1.20 | |
| Sampling, QC, buffer, freight, duties | ~$4.46 | combined |
| TOTAL LANDED | $31.73 | |
| Retail (4–5x) | $127–$159 | |
| Gross Margin | ~75–80% |
Worth knowing
The snap crotch adds $2.50–4.00 CMT over an equivalent standard jersey top — that's the entire cost of what makes a bodysuit a bodysuit.
The bodysuit is in the same production run as the T-shirt range — no factory change required.
The takeaway
If you're already producing T-shirts, a bodysuit isn't a new sourcing project — it's a small CMT adder on infrastructure you already have. That's exactly why it's one of the most repeat-purchased items in a DTC jersey range.
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