How to make a pair of socks? The secrets of a little-known manufacturing process

Did you know? To make a sock, almost ten steps are necessary. Behind this small everyday accessory lies a complex and fascinating manufacturing process, combining tradition and technology. In this article, Maison Broussaud - French sock manufacturer since 1938 and 3 generations - takes you to discover the key steps in the manufacture of a sock. From the raw material to the finished article, the process of making a pair of socks is more complex than you might think. Come with us to discover the behind the scenes of this little-known production!

Step 1: Imagine the sock before making it

Before manufacturing, the future sock is first designed on computer software. Each new model passes through the expert hands of industrial designers. In concrete terms, one pixel on the computer is equal to one stitch of the future sock. A technical know-how that we keep in our factory in Limousin. After developing a computer program corresponding to the desired design, a prototype is knitted which is called a sample. Once the sample has been validated, a few weeks are necessary to produce a new model.

2nd step: raw materials, choice of quality

The starting point for all textile manufacturing lies in the choice of raw materials. Faithful to "Made in France" since its creation, La Maison Broussaud has chosen transparency by obtaining the Origine France garantie certification. All our socks are entirely knitted and manufactured in our own workshops in France. To remain consistent with these commitments, we favor the short circuit for all our suppliers and service providers. All our packaging is made in our region, Limousin. As for the choice of our raw materials, we try as much as possible to turn to European countries to limit our impact.

Step 3: Knitting the socks

Knitting is the first step in the actual manufacturing process. Our technicians - called hosiery workers - set up the machines that will produce your future socks in the form of tubes. This is called circular or tubular knitting. Circular knitting is a technique that produces a seamless and highly elastic textile. Unlike flat knitting, there are no distinct edges, which provides greater elasticity, comfort and aesthetics, ideal for socks. The absence of seams prevents friction and irritation. To obtain a tube, the stitches are knitted one by one, row by row from top to bottom. This tube knitting is done in one go, without seams on the sides, encompassing the heel but leaving the toe open.

Step 4: Returning

Knitted, the sock comes out of the knitting machine right side up, but the next step requires it to be turned inside out. Each sock is then placed in a tube that sucks it up to turn it inside out. Turning prepares the next finishing step: darning.

Step 5: Re-meshing the sock

After knitting, the sock undergoes several finishing steps. The socks come out of the knitting machines in the form of tubes open at each end. The darning consists of sewing the toe.

Step 6: Forming

Forming is the "ironing" step. Each sock is placed by hand on a metal foot form. The whole thing goes through a steam machine to tighten the stitches and give the sock its final shape. The longer the sock remains in the steam, the more the stitch shrinks. This is why there can be a very slight difference between two socks from the same production.

Step 7: careful quality control

Each sock is then hand-checked by the expert hands of our quality controllers. Each one must be carefully inspected before being packaged. Then, it is a question of putting them in pairs. Since they can be slightly different following the shaping, we try to assemble 2 socks as identical as possible so as not to end up with one foot larger than the other.

The manufacture of a sock is a complex process that requires know-how and cutting-edge technology. For this, Maison Broussaud has the honor of being labeled Entreprise du Patrimoine Vivant . From the choice of raw materials to quality control, each step contributes to the quality and comfort of your socks, which have become real fashion accessories. Discover our collection of socks made in France for men or socks for women in plain, patterned, sporty colors...