Those who know me know that I've been sewing for years. It's been over 30 years actually as my Nan taught me the basics when I was 12, and sewing has been a part of my life ever since.

My last job was also in clothing production, where I worked for 9 and a half years, initially on industrial sewing machines, with occasional pattern making and manual cutting, which in September 2020, evolved in computerised pattern making and cutting, using the Style CAD system as well. 

Outside of work, however, most of my sewing has been for my children. Over the years I've made baby dresses, little boys button ups shirts and pants, christening outfits, dress-up costumes, party dresses, flower girl dresses, graduation suits and the occasional graduation dress. Alongside those were dancing leotards and tutus, and swimwear.

Basically if there was an opportunity to design a garment, we took it. 

Since moving to my new town, I have not advertised any of my work. Online most people know me primarily as a milliner. So yesterday when I took my children to the pool for my sons swimming lesson was a bit of a pleasant surprise. 

One of my daughters was approached by a lovely lady complimenting her swimmers. My youngest daughter looks a lot like me so it didn't take the lady long to realise she was my child and she asked me where I bought them.

Long story short, I told her I made them, my daughter designed them, I bought the fabric online but from within Australia and I made them. She asked if I sold my creations and I said "Not Yet!"

She approached again as she was leaving the pool and told me that if I do venture that way, let her know, she swims there every day and is very interested. 

Truthfully, every time I go to the pool, which is every week, I think about making swimwear, not just for myself but for others as well. As adults we buy the pretty swimmers for our little girls but many of us end up wearing fairly  basic one-pieces ourselves. Personally, I actually don't wear women's one-piece swimmers because I am too short, So I tend to make my own two piece designs instead, but my lack of height is a different topic.

What I would  love to address someday, if I do begin creating swimwear for sale, is designing for different heights, different bodies, and different aesthetics.

That conversation at the pool led directly to today's post.

Swimwear might look complicated, but it isn't particularly difficult to make once you understand the materials and techniques involved. So today I thought  I'd walk you through the process  I used to research, design and create swimwear for my children.

I'll share some of my favourite patterns for both women and children, my preferred fabrics, and I'll link to some of my favourite creators on YouTube videos if you'd like to make swimwear for yourself. I'll also include a simple costing breakdown for my children's swimsuits so you can see what's involved.

And if you're interested in making leotards, the good news is the same fabrics and techniques apply

So, let's jump into how I made my children's swimwear.

The Brief

My daughters and son needed swimwear suitable for both swimming lessons and recreational use. The design required a balance of comfort, durability, ease of movement, and age-appropriate aesthetics. Communication with my children throughout the process ensured their preferences for style, colour, and fit were included, which helped guide the final designs.

Research and Inspiration

When it came time to begin researching fabrics and techniques, I already had some experience working with stretch fabrics from previously making dance leotards. I also had leftover lycra from those projects, which meant I was already familiar with at least one supplier offering colourful, performance-appropriate fabrics.

My first step was revisiting that supplier, Glitter & Dance, to see what options were available. From there, I expanded my research with an online search for other swimwear fabric suppliers and discovered Boo Designs, an Australian company known for swimwear patterns and stretch fabrics. This was around 2018 or 2019.

Because swimwear construction techniques can differ slightly from standard garment sewing, I decided to further develop my skills by participating in one of their swimwear sew-along projects using the Embrace Togs pattern. This allowed me to refine techniques specific to swimwear construction, such as working with stretch fabrics, applying elastic, and achieving clean, durable finishes.

Before starting the sew-along, I began with a basic Jalie pattern that I had previously used when making leotards, just to confirm sizing. Since leotards and swimsuits use similar fabrics and require similar levels of stretch and movement, this provided a reliable starting point for fit. I then purchased the sew-along kit from Boo Designs and worked through the process.

Once the technical side was established, my daughters and I looked through Pinterest for visual inspiration. This helped us explore colour combinations, style ideas, and design details that appealed to them. Including them in this stage made the process collaborative and ensured the final designs reflected their personalities.

During the research phase, I also explored pattern options beyond what I already owned. In addition to commercial pattern companies, I looked at independent designers and downloadable patterns on Etsy, which has become a popular platform for a wide variety of garment patterns. While researching swimwear, I found several options for boys’ swim trunks and rash vests, which helped me explore different construction approaches and design possibilities for my son’s swimwear.

Unfortunately, the swim trunks pattern I used is no longer available, so I am unable to share that specific resource. However, it was sourced from the same designer as the rash vest pattern, which is linked below.

The Patterns I Used

Concept Development and Collaboration

Once the research phase was complete, I moved on to developing the design concepts for each child’s swimwear.

To begin, I asked each child to select approximately five potential fabric options, including my son. Presenting multiple options allowed them to actively participate in the design process, while ensuring the selected fabrics met the technical requirements of swimwear, such as stretch, durability, and chlorine resistance. My daughters particularly enjoyed choosing colours and prints, which made the final garments feel personal and reflective of their preferences.

Costing considerations and design decisions were also discussed with the end users throughout the project. This included consultation around design features such as colour combinations and garment styles, including the cost implications of multi-colour designs compared to simpler options, as well as the differences in material and production requirements between one-piece garments and bikinis. These discussions informed decision-making and ensured the final garments balanced cost, functionality, and user preferences.

For the base pattern, I used Jalie 3349, which I had previously used when making leotards. As leotards and swimsuits share similar construction requirements and rely on stretch fabrics, this pattern provided a reliable starting point for sizing and fit. Using this base pattern, I drafted individual pattern pieces for each child, adjusting proportions where necessary to accommodate differences in size, comfort, and movement.

Although I did not produce formal fashion sketches for this project, the concept development stage included selecting fabrics, discussing style preferences, and determining design details such as seam placement, lining, and overall silhouette.

My experience participating in the Embrace Togs swimwear sew-along with Boo Designs was particularly helpful at this stage. Having already developed an understanding of key swimwear construction techniques, I was able to focus more on refining design decisions and fit, rather than learning the technical process from the beginning.

This collaborative approach ensured the final designs balanced practical performance requirements—durability, stretch, and comfort—with the aesthetic preferences of the children who would be wearing the garments.

I also explored swimwear fabrics from another Australian small business during the research phase. While I am unable to recall the name of the supplier, they offered a range of pre-order fabrics across multiple bases, including cotton knits in various weights, spandex suitable for swimwear, and peach skin fabrics for board shorts. If I locate this information in the future, I will update this post to include the supplier details.

While this project was not undertaken for commercial profit, costing considerations were consistent with industry approaches, including awareness of profit margins, cost recovery, and break-even considerations.

Click Here to go to Fabrics from Boo Designs

Some of the inspiration pictures my daughters found on Pinterest.

  • A picture of a swimsuit which was used an inspiration for custom swimwear.
  • A picture of a swimsuit which was used an inspiration for custom swimwear.
  • A picture of a swimsuit which was used an inspiration for custom swimwear.
  • A picture of a swimsuit which was used an inspiration for custom swimwear.
  • A picture of a swimsuit which was used an inspiration for custom swimwear.
  • A picture of a swimsuit which was used an inspiration for custom swimwear.
  • A picture of a swimsuit which was used an inspiration for custom swimwear.
  • A picture of a swimsuit which was used an inspiration for custom swimwear.
  • A picture of a swimsuit which was used an inspiration for custom swimwear.

Design Concepts

Three initial design concepts were developed for the swimwear garments, based on inspiration gathered from Pinterest and initial discussions with the end users.

Concept 1: Fully Lined Swimwear

A fully lined swimwear garment designed to maximise comfort, modesty, and durability. This concept focused on structured support and a smooth internal finish to reduce irritation against the skin.

Concept 2: Partially Lined Swimwear

A partially lined design incorporating lining in key areas only. This approach aimed to balance comfort and modesty while reducing material usage and production time, making it a more cost-effective option.

Concept 3: Unlined Swimwear

An unlined swimwear design using high-quality stretch swimwear fabric. This concept prioritised simplicity, flexibility, and reduced material use, while still maintaining function through appropriate construction techniques.

All three concepts were evaluated in relation to functionality, comfort, cost, and suitability for the intended users. The final designs were selected based on their ability to best meet the requirements of the brief.

Prototyping, Fit Testing and Pattern Adaptation

Once the design concepts and fabrics were selected, the next stage was testing the patterns and refining the fit for each child. I used leftover lycra from previous leotard projects to create test garments, which allowed me to experiment with sizing adjustments and construction techniques without risking the final fabrics.

The base pattern was Jalie 3349, which provides clear instructions for adjusting proportions. Using these guidelines, I adapted the pattern for each child individually:

Daughters:

One is tall and slim, while the other is shorter with a different body shape. Small adjustments were made to ensure a comfortable fit and full range of movement for each.

Son:

Drawing on previous experience from knitting his jumpers as a toddler, I lengthened the torso of his rash vest to suit his longer torso and shorter legs. This ensured the garment stayed in place during swimming and provided improved coverage.

Testing with scrap fabric also allowed me to refine seam placement, check stretch and recovery, and confirm sizing adjustments before cutting into the final fabrics.

Materials and Construction Choices

During the research stage, I explored lining options, as lining can significantly improve comfort and modesty in swimwear.

After comparing several options, including a nude lining from Spotlight and a white lining from Glitter & Dance, I initially used the nude lining I already had from previous dance costume projects. I then purchased the white lining from Glitter & Dance to use in future garments, as it was noticeably softer and more suitable for children’s swimwear. The fabric had a smooth hand feel, making it comfortable against the skin while still providing the opacity required.

Elastic is another critical component in swimwear construction, as it determines how well the garment stays in place during movement and in water. For this project, elastics were sourced from both Booby Traps and Spotlight Stores. While both were usable, the elastic from Booby Traps was preferred due to its more consistent performance in swimwear applications.

Lycra, spandex, and elastane are terms often used interchangeably to describe the same type of fibre; however, Lycra is a registered brand name. These fibres have a limited lifespan due to the gradual breakdown of elastane over time, which can be accelerated by exposure to sunlight, chlorine, and heat.

To preserve the quality of these materials, fabrics were stored out of direct sunlight in plastic containers within a cupboard. This helps maintain the integrity of the fabric and extends its usability prior to construction.

Materials and Haberdashery

Production, Practical Use, and Durability

Previous industry experience and prior garment production, including the construction of dance leotards, informed production planning and cost-efficiency strategies. Based on this experience, garments were produced using a workflow that grouped items by colour and construction stage. Processes such as pattern making, cutting, overlocking, and topstitching were completed in batches rather than individually.

This method reduced time spent transitioning between machines, minimised thread changes, and improved overall efficiency. Completing each stage across multiple garments before progressing to the next also supported workflow consistency and productivity.

Using approximately five new fabrics per child, along with leftover materials from previous projects, I produced multiple swimsuits for each child. In total, each daughter received around eight swimsuits, and six sets were made for my son. Producing multiple garments was a practical decision, as swimwear fabrics such as lycra naturally degrade over time with repeated exposure to sunlight, chlorine, and stretch. Having several garments available helped extend the lifespan of each individual piece.

This approach also ensured that during the summer holidays—when we often visited the pool daily—clean, dry swimwear was always available without the need to constantly wash and dry the same items. Some leftover fabric was also used to make a few bikinis for myself, maximising material efficiency and reducing waste.

A few years later, remaining fabrics were used to create replacement swimsuits as the children outgrew their originals. The fabrics and construction methods proved durable, with many of the original garments still in good condition after years of use. This demonstrates the effectiveness of careful material selection, pattern adaptation, and quality construction techniques.

Given the success of this project in terms of both functionality and longevity, I plan to repeat the process as the children continue to grow and their swimwear needs evolve.

Work health and safety practices were applied throughout the production process. When operating sewing equipment, appropriate precautions were taken, including wearing closed-toe footwear, securing long hair, and avoiding loose clothing or jewellery that could interfere with machinery.

As garments were custom-made, fabric was cut in a single layer using scissors, reducing the need for more complex cutting equipment while maintaining control and safety. The work environment was organised to support safe movement between tasks and equipment./

Some photos from my first few pieces.

  • A picture of a children's swimsuit.
  • A picture of a children's swimsuit.
  • A picture of a children's swimsuit.
  • A picture of a children's swimsuit.
  • A picture of a children's swimsuit.
  • A picture of a children's swimsuit.
  • A picture of a children's swimsuit.
  • A picture of a children's swimsuit.
  • A picture of a children's swimsuit.

Sourcing Materials

Below is an example of a resources table used to track where materials and supplies are sourced. A downloadable blank template is also provided for reference.

Boo Designs, Glitter & Dance, and Booby Traps are Australian-based businesses, while Emerald Erin is Canadian-based. Ohhh Lulu and Evie La Luve are also international suppliers, with their patterns available as digital downloads. This reduced both waiting times and international postage costs, supporting more efficient project planning.

Shipping structures varied between suppliers and were considered during sourcing decisions. Glitter & Dance calculates shipping based on weight, while Booby Traps offers free postage on orders over $150 and Boo Designs offers free postage on orders over $250. Booby Traps also provides bulk pricing for elastic, with discounts applied for larger quantities (10% off for 100–249 metres, 15% off for 250–499 metres, and 20% off for 500 metres or more). These pricing structures were taken into account to optimise cost efficiency and reduce overall production expenses.

Shipping costs, minimum order requirements, and ethical sourcing considerations were all factored into supplier selection. Orders were placed and tracked to ensure timely delivery, supporting production schedules, and shipping costs directly influenced final purchasing decisions.

Ethical and sustainable considerations were applied through material selection, efficient use of resources, and bulk purchasing to minimise waste. Communication with suppliers was primarily conducted through online platforms, with product descriptions and available information used to compare options where direct communication was limited.

Materials were ordered, received, checked, and stored in accordance with standard production and handling practices, and in line with fabric-specific requirements.

Cost and Budget Considerations

Cost and budget were key considerations throughout the design and production process. A comparison was made between lined and unlined swimwear to assess the impact on material usage, production time, and overall cost.

To further manage costs, practical decisions were made regarding material usage. For overlocking, thread colours were selected to closely match groups of garments rather than perfectly matching each individual fabric. All pink garments used the same overlocking thread colour, and all blue garments used a consistent thread colour. As these seams are not visible on the finished garments, this approach reduced the need for multiple thread colours while maintaining a professional finish.

Topstitching thread was the primary thread adjusted to match each garment more precisely, as it is visible on the outside of the finished product.

Materials such as elastic and lining were purchased in bulk to maximise usage and reduce overall costs, including postage and handling expenses. This approach improved efficiency while ensuring consistency across garments.

Lined garments required additional fabric and construction time, increasing production costs; however, they provided improved comfort, durability, and modesty. Unlined garments reduced material costs and production time, making them a more cost-effective option, but with reduced structural support.

Costs were considered in relation to:


  • materials and fabric selection

  • labour and production time

  • construction methods and techniques

  • overall quality and functionality

Differences between small-scale and large-scale production were also considered based on previous industry experience. Small-batch production, as used in this project, allows for greater flexibility, design variation, and customisation to individual requirements, but can result in higher per-unit costs due to reduced efficiency.

In contrast, large-scale production enables increased efficiency and reduced cost per unit through repetitive processes and standardisation; however, it limits design flexibility and requires consistency across all garments. The selected small-scale approach was appropriate for this project, as it prioritised fit, design variation, and quality over mass production efficiency.

Design decisions were adjusted throughout the process to ensure the final garments achieved a balance between quality, cost-effectiveness, and suitability for purpose. Suppliers were selected based on their ability to meet requirements for quality, cost, and availability.

Resource Table Template Download

Costing Children’s Swimwear: Labour, Materials, and Ethical Considerations

When producing small-batch swimwear for children, it is important to balance a range of cost factors while maintaining quality and functionality. These considerations include:


  • Material costs – fabrics, linings, and elastics

  • Labour costs – sewing time, level of skill required, and pattern adjustments

  • Overheads – notions, thread, and cutting tools

In addition to direct costs such as materials and labour, indirect costs were also considered. These include machine usage, electricity, tool wear, and time spent on sampling and adjustments. While not always directly itemised, these factors contribute to the overall cost of production and were considered when evaluating the efficiency of the project.

Costing Table Download

Cost Analysis & Decision

Although producing lined swimwear requires higher material and labour costs, the increased quality, comfort, and modesty justify the additional expense. The skill required to insert linings and manage stretch fabrics contributes to a professional finish that is often not achievable with mass-produced garments.

Small-batch production also supports ethical and sustainable practices. Sourcing high-quality fabrics and using careful construction methods helps reduce waste, ensures suitability for children’s wear, and improves overall garment longevity. This approach prioritises quality and functionality over mass production efficiency, aligning with both practical and ethical considerations.

Production Considerations

Several production considerations and constraints were taken into account during the creation of the swimwear garments.

The use of stretch swimwear fabrics required appropriate construction techniques to ensure both durability and flexibility. Seams were finished using an overlocker to prevent fraying and to allow for stretch, while elastic was applied using an overlocker and secured with a three-step zigzag stitch to maintain elasticity and garment integrity.

Production constraints included:


  • the need for stretch-compatible construction techniques

  • the limitations of domestic sewing equipment for certain stages

  • ensuring garments maintained shape and function after construction

These constraints were addressed through the use of appropriate industrial and domestic sewing techniques, resulting in a professional and functional finish that met the requirements of the garments.

Additional Pattern and Fabric Resources for Adult Swimwear

While the children’s swimwear in this project was developed using Jalie 3349, I have also experimented with other swimwear and lingerie sewing patterns when making garments for myself.

Some of my personal swimwear patterns come from Evie La Luve, a designer who specialises in lingerie and swimwear patterns. Their designs focus strongly on fit and construction techniques, making them particularly useful when learning how to work with stretch fabrics and elastic finishes.

Ohhh Lulu Sews is another favourite lingerie designer. While not specifically labelled as swimwear, many of their designs can be adapted for this purpose. Their patterns range from more edgy and playful styles to softer, more classic designs.

I have also sourced specialty fabrics and notions from Emerald Erin. I have used lingerie fabrics purchased from Emerald Erin in previous projects and found them to be exceptionally high quality, which is why I was interested in exploring their swimwear materials as well.

One of the aspects I particularly enjoy about Emerald Erin’s work is the educational content shared online. Through platforms such as Instagram, she regularly posts videos demonstrating elements of her patternmaking and sewing process. These behind-the-scenes insights are valuable for sewists who want to deepen their understanding of garment construction.

As an added bonus, her posts occasionally feature her very cute puppy, which adds a light and enjoyable element to the learning process.

To visit Emerald Erin's Instagram Page and see all her helpful videos

Patterns I Used for My Own Swimwear

More patterns by Evie La Luve

Some videos that you might find helpful from my favourite creators

As I continue developing my swimwear designs, these are some of the more advanced notions and hardware I’m interested in exploring to refine fit, structure, and finish. These are all available from boobytraps.com.au

Specialized Swimwear Components

Reflection

This blog post serves as both a visual and written presentation of the design process, functioning as a storyboard to communicate the development of the swimwear garments. The presentation includes initial inspiration and design concepts, fabric and material selection, work-in-progress images, construction processes and techniques, and the final completed garments. My intention in sharing this process is to encourage and inspire others to explore making their own swimwear.

Looking back, this project brought together many different skills that I have developed over the years. My earlier experience making dance leotards, along with participation in a swimwear sew-along, provided a strong foundation and confidence to approach swimwear construction with a clear understanding of fabrics, techniques, and finishing methods.

Designing these garments also provided an opportunity to work with pattern adjustments and fit, which is an area I particularly enjoy. Adapting patterns to suit each child’s proportions and individual preferences allowed me to revisit pattern-making skills and refine them in a practical context.

Throughout the design process, I also considered elements such as colour, balance, and proportion to create visually appealing garments, while ensuring functionality and suitability for the intended use.

At the same time, creating these garments for my children made the process collaborative and creative. Their input helped shape the choice of colours, prints, and final designs, while I focused on the technical aspects such as fit, durability, and construction.

The project also reinforced the importance of thoughtful material selection and industry considerations. Choosing appropriate swimwear fabrics, comfortable linings, and reliable elastics ensured the garments met both functional and quality expectations. Cost was also considered during the sourcing of materials, including decisions such as purchasing elastic and lining in bulk, and selecting thread colours that could be used across multiple garments to improve efficiency and reduce costs.

Although the original goal was to create practical swimwear for my children, the process itself became part of my broader creative journey. It combined research, design, problem-solving, pattern adaptation, and garment construction in a way that reflects how I naturally approach textile projects.

Looking back, this project feels like one small step in an ongoing exploration of design, making, and craftsmanship. It also highlights how swimwear design sits within the broader textile and fashion industry, where functionality, durability, and aesthetics all play important roles. This project is a reminder that some of the most valuable learning experiences often begin with something as simple as creating everyday garments for the people we care about.