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Ski Base Layer & Fleece Mid-Layer Manufacturer

Base layers and mid-layers are the warm, dry part of a ski outfit: the base layer moves sweat away from the skin and the mid-layer traps warm air under the shell. Mr Balaclava manufactures merino and polyester base layers and polar, micro and sherpa fleece in-house under your label, from 50 pieces per design and with a standard lead time of about 14 days.

Updated

Man wearing a grey textured base layer top and matching bottoms with a fitted silhouette
  • 50 pcsMinimum order
  • 14 daysStandard lead time
  • 100K pcsMonthly capacity
  • ISO 9001Certified (Eco Jersey Limited)
  • SedexMember (Eco Jersey Limited)

Specifications

Base layer and fleece specifications

What we can build into base layers and fleece mid-layers, and the terms that apply to every order.

Base layer stylesCrew-neck and half-zip tops, leggings, sets; long or short sleeves
Base layer fabricsMerino wool jersey, merino blends with nylon or elastane, moisture-wicking and brushed-back polyester jersey
Fleece stylesFull-zip jackets, quarter-zip and half-zip pullovers, hoodies and vests
Fleece fabricsPolyester polar fleece, microfleece and sherpa fleece; anti-pilling finishes
WeightsLight to midweight base layers; fleece weights set per style; both confirmed in the sample
ConstructionClose, stretchy fit; flat or flatlock seams; printed neck labels
How it is madeCut, sewn, finished and inspected in-house
BrandingEmbroidery and patches on fleece; heat transfer, sublimation on polyester and printed neck labels on base layers; woven labels and hang tags
SizesAll sizes: men's, women's, unisex and kids', graded to your size chart
Minimum order50 pieces per design
Lead timeApproximately 14 days after sample approval as standard; the confirmed schedule is agreed for each order

Buyer's guide

Merino or polyester base layers?

Merino wool is the premium choice: warm for its weight, comfortable when damp and naturally odour-resistant, so it can be worn for several days. Merino blended with nylon or elastane is stronger and holds its shape. Polyester base layers dry faster, cost less and can be printed edge to edge by sublimation.

Fit matters as much as fabric: a base layer only wicks sweat if it touches the skin, so it is cut close and stretchy, with flat seams that do not rub under a jacket or backpack. Compare the fabrics on our merino and performance fabrics pages.

  • Ski and outdoor brands

    Merino and synthetic base layer ranges under your label.

  • Team and school kits

    Printed base layers in team colours under race suits and jackets.

  • Retail sets

    Top and legging sets in retail packaging.

  • Workwear

    Thermal layers for outdoor staff and cold-weather work.

Compare

Which layer fabric fits your range?

The fabrics buyers request most for base and mid-layers, and what each one is best at.

FabricLayerStrengthsBest for
Merino jerseyBase layerWarm for its weight, comfortable when damp, odour-resistantPremium ranges and multi-day trips
Polyester jerseyBase layerDries fast, costs less, can be sublimation-printedTeam kits, value ranges and printed designs
MicrofleeceMid-layerThin and light; fits under a ski shellA close mid-layer for skiing
Polar fleeceMid-layerThicker and warmer; the classic fleece jacket fabricFleece jackets, staff and team wear
Sherpa fleeceMid-layer or worn on its ownDeep, curly pile with a cosy, fashion lookAprès-ski and streetwear jackets

Fleece mid-layers

Polar, micro or sherpa fleece?

Microfleece is thin and light, ideal as a close mid-layer under a ski shell. Polar fleece is thicker and warmer, the classic fleece jacket fabric. Sherpa fleece has a deep, curly pile with a cosy, fashion look and works as an après-ski or streetwear jacket as much as a mid-layer.

Fleece stays warm when damp and dries quickly, and it takes embroidery and patches well. Our fleece garments are made in-house. For the fabrics, see the fleece family in our Material Library.

Two men in colour-block quarter-zip fleece pullovers in teal and pinkClose-up of a green sherpa fleece jacket with a snap front

Fleece fabrics in our Material Library

The layering system

How base and mid-layers work under a shell

Skiers stay warm by combining layers rather than wearing one thick jacket. The base layer sits next to the skin and moves sweat outwards; the mid-layer traps warm air and can be added or removed as the weather changes; the outer shell keeps snow and wind out. Each layer only works if the one beneath it can pass moisture on, so base layers are cut close and mid-layers stay breathable.

A complete range offers all three in matching colours. Pair these layers with our ski jackets and ski pants and suits.

Man in a fitted black long-sleeve base layer topWoman in a black half-zip thermal base layer top with red flatlock seams

Customization

Build your base and mid layers

Every part of the design is yours. Our design team sends a mockup of each logo and label placement, and every detail is confirmed in a tech pack before sampling.

  • Choose the fabric

    Merino, merino blend or polyester for base layers; polar, micro or sherpa fleece for mid-layers.

    Material Library

  • Choose the cut

    Crew or half-zip tops and leggings; full-zip, quarter-zip, hoodie or vest fleece; your size chart.

    Sizing and fit

  • Add colour and details

    Solid colours, colour-blocking, contrast flatlock seams, sublimated prints on polyester, pockets and zips.

  • Brand it

    Embroidery and patches on fleece, printed neck labels that do not rub, woven labels and hang tags.

    Customization and branding

How ordering works

Three steps to your order

Every order starts with your brief and ends with tracked delivery.

  1. Send your brief

    Tell us the garment, fabric, waterproof rating, sizes, quantities, branding and deadline. We reply with a quote and suggest a suitable build.

  2. Approve the sample

    We confirm every measurement, fabric, colour and logo placement in a tech pack, then make your sample. Samples are paid 100% in advance.

  3. Production and delivery

    Standard production lead time is approximately 14 days after sample approval. Every piece is inspected, packed to your specification and shipped with tracking.

Request a ski wear quote See the full manufacturing process

B2B catalog

Base and mid layers from our B2B catalog

Developed styles you can order with your own branding, or use as the starting point for a custom design.

Browse all base & mid layers in the B2B catalog

More categories

Other ski wear categories

See the other ski wear categories we make, or compare the whole range on the custom ski wear page.

FAQ

Base layers and fleece: frequently asked questions

What is the minimum order for base layers and fleece?

The minimum order is 50 pieces per design.

Merino or polyester: which should we offer?

Merino is warmer when damp and resists odour; polyester dries faster, costs less and can be sublimation-printed. Many ranges offer both.

Can base layers be printed?

Yes. Polyester base layers can be sublimation-printed edge to edge from your artwork; merino takes smaller heat-transfer logos.

Do you make the fleece garments yourselves?

Yes. Our fleece jackets and pullovers are made in-house, from cutting and sewing to finishing, inspection and packing.

Which branding works best on fleece?

Embroidery and woven or rubber patches suit the pile of fleece best; heat transfer works on smoother microfleece.

Can a fleece be worn under a ski jacket?

Yes. Microfleece and lighter polar fleece are made to fit under a shell as a mid-layer; sherpa is usually worn on its own.

Do you make matching tops and leggings?

Yes. Tops and leggings are made from the same fabric and can be sold separately or as a set.

How long does base layer and fleece production take?

Standard production lead time is approximately 14 days after sample approval. Actual lead time depends on the product, quantity, customization and material availability, and the confirmed schedule is agreed for each order. Express shipping by DHL, FedEx or UPS then takes 3–6 working days.

Buyer guides

Further reading

Guides from the Journal on ski clothing and fleece.

Product quick view

Product quick view

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