Custom Letterman Jackets: Your Ultimate Material and Design Guide

Custom letterman jackets first appeared in 1865 as uniforms for Harvard’s baseball team. Over time, these classic pieces evolved from simple wool sweaters into iconic symbols of pride, style, and individuality. What once served as a warm outer layer has now transformed into a powerful fashion statement blending nostalgia with street-style appeal.

Today, custom varsity jackets are no longer reserved for athletes alone. They’ve become a canvas for creativity, offering endless possibilities in materials, colors, and personalization. In this guide, we’ll dive into the fabrics, designs, and customization options that make these jackets so special. So, if you’ve ever dreamed of owning one, keep reading you’re about to discover why custom letterman jackets are timeless must-haves!

What Is a Custom Letterman Jacket?

A custom letterman jacket also called a varsity or baseball jacket is a stylish piece of outerwear originally worn by high school or college sports teams. Think of it as the perfect blend between a bomber and a track jacket. Traditionally, these jackets feature a wool body with leather or faux-leather sleeves, ribbed cuffs, and button closures.

What makes them custom are the letters, patches, and embroidery each symbolizing achievement, team spirit, or school pride. Every letter, emblem, or number tells a story, representing milestones and memories that wearers carry with pride.

Why Are Custom Letterman Jackets So Popular?

The popularity of varsity jackets skyrocketed thanks to Hollywood. From classic teen dramas to modern-day fashion icons, letterman jackets have appeared in countless movies and shows, becoming synonymous with youth, confidence, and belonging.

But their appeal goes far beyond pop culture. Here’s why they’re still trending:

• Timeless Legacy: Once a symbol of school pride, now a versatile fashion statement.
• Unisex Appeal: Perfect for both men and women casual yet effortlessly cool.
• Versatility: Pair it with jeans, skirts, or even dresses these jackets complement any outfit.
• Personal Expression: Customization allows you to create something truly yours from initials to color combinations.

Whether you’re going for a relaxed, sporty vibe or a chic streetwear look, a letterman jacket instantly elevates your outfit while keeping that nostalgic charm alive. 

Design Guide for Creating Custom Letterman Jackets

Now that you have a solid understanding of what letterman jackets are, it’s time to dive into the fun part designing your own! By following this design guide from Varsity Made, you’ll be able to craft a stylish, personalized varsity jacket that perfectly represents your school spirit or personal style. Here’s everything you need to know to get started:

Your Choice of Material Matters the Most

The fabric you choose will define the overall look, comfort, and durability of your custom letterman jacket. Traditionally, varsity jackets were made from cotton fleece with leather sleeves, but today, you have a much wider selection of materials to pick from. Below are some of the most popular options used for modern designs:

1. Real Cowhide Leather

A timeless favorite, real cowhide leather is one of the most commonly used materials in varsity jackets today. It’s affordable, durable, and offers excellent protection against harsh weather. Another plus it’s naturally water-resistant and supports embroidery or patchwork beautifully. Available in a variety of colors and finishes, cowhide leather adds a touch of classic elegance to any jacket, making it an unbeatable choice for customization.

2. Faux Leather

If you’re looking for a more budget-friendly and animal-friendly option, faux leather is the way to go. Although it lacks the long-term durability of genuine cowhide, it still mimics the same sleek appearance at a fraction of the cost. Many modern custom letterman jackets feature faux leather sleeves, offering the same trendy style while staying cruelty-free a major plus for eco-conscious wearers.

3. Wool

When it comes to warmth and resilience, wool remains unmatched. Its tightly woven texture and heavy brushing give it a refined, polished appearance. Wool varsity jackets are particularly popular in colder climates because they provide excellent insulation without feeling overly bulky. If you’re after a classic, high-quality look that stands up to the elements, wool is a fantastic choice.

4. Cotton Fleece

Soft, lightweight, and skin-friendly, cotton fleece is ideal for people who have allergies or prefer breathable materials. Think of it as a more affordable and comfortable alternative to wool. It’s easy to wear, easy to maintain, and still offers great warmth retention. For casual wear or mild weather, cotton fleece is one of the most practical and comfortable options available.

5. Polyester Satin

For those who love a sleek and shiny finish, polyester satin brings color and sophistication to the table. Known for its vibrant range of hues and smooth texture, this material makes your jacket both eye-catching and comfortable. The synthetic fibers are extremely durable, giving your custom letterman jacket a long-lasting life while keeping it soft to the touch. 

Material for Sleeves & Inside Lining

To keep things simple, you can use the same fabric for the sleeves as you do for the jacket’s body. However, there’s one exception if the body is made of melton wool, it’s best to go with leather sleeves. This combination not only adds contrast but also gives your varsity jacket a bold, premium look.

Remember, sleeve stitching plays a huge role in how your jacket turns out. Poor stitching can completely throw off the design and structure. Essentially, the stitching defines the quality of a varsity jacket neat, strong seams ensure durability and style.

When it comes to the inner lining, you can choose from three main materials: cotton, polyester satin, and quilted lining. Each has its own advantages:

• Cotton provides natural warmth and breathability.
• Polyester satin feels soft, smooth, and gives a sleek finish.
• Quilted lining combines the benefits of both it’s warm, soft, and perfect for harsh winter climates.

If you live in a cold region, quilted lining is undoubtedly your best bet for both comfort and insulation.

Style Selection of Custom Letterman Jackets

Style is what transforms a simple jacket into a timeless fashion statement. The right styling adds depth, personality, and modern appeal to your custom letterman jacket. Below are some useful tips for styling both the body and the sleeves:

Style Selection for the Body

When choosing a front closure, you generally have two options zip-up or buttoned.

• A zip-up closure offers a practical and functional style, keeping you well-protected against chilly weather.
• On the other hand, a buttoned closure gives your jacket a more classic and fashionable edge ideal if you prefer a sleek, trend-forward look.

The choice ultimately depends on your personal style functionality or fashion flair.

Style Selection for the Sleeves

Sleeves can dramatically change the overall look and comfort of your jacket. There are two main types of sleeve designs: Set-in and Raglan.

• Set-in sleeves are stitched at the shoulder, giving the jacket a structured and professional appearance. They’re perfect if you want a clean, formal finish.
• Raglan sleeves, however, are made from a single continuous piece of fabric that extends to the collar, offering a sportier and more flexible fit. Athletes and active wearers often prefer this style for better movement and comfort.

Whether you go for set-in sophistication or raglan performance, your sleeve choice should reflect your personality and purpose that’s what makes your custom letterman jacket truly yours.

Colors for Custom Letterman Jackets

Traditionally, letterman jackets came in just two contrasting colors a simple yet timeless combination. Today, however, creativity knows no bounds. You can still stick with the classic two-tone style or experiment with bold and modern color combinations. Many students prefer using their school or college colors, aligning the jacket with their institution’s spirit and logo.

That said, the current fashion trend leans toward a maximum of three colors for a clean and balanced look. The key is harmony your chosen shades should complement one another rather than clash. Every color you select should enhance the overall appeal of the jacket.

Remember, customization isn’t limited to the body or sleeves. You can choose unique colors for every detail from buttons or zippers to the hood, pockets, and inner lining. Every element can reflect your personal flair while staying true to your team or school identity.

Print Designing the Letterman Jacket: The Final Step

This is where your creativity truly shines the finishing touch that brings your jacket to life. Let your imagination take over and design freely with Bomber Jacket Builder or any custom design tool you prefer.

However, a few design tips can help keep your jacket stylish and balanced:

• Keep your college or team name at the front center, ensuring it stands out as the main highlight.
• Limit text to 12 characters for a clean and appealing look; overcrowded prints can ruin the aesthetic.
• The pocket area is perfect for small details like initials, logos, symbols, or mascots.
• For the back center, go bold with the player’s name, number, or team name it’s where attention naturally goes.
• The left sleeve is ideal for the player’s number, while the right sleeve can feature the graduation year.
• The right chest area works great for adding the team mascot or emblem.

And for those who want an extra touch of personality, embroidered patches are a must-have. Add them anywhere you like sleeves, chest, or even the back to give your jacket that signature, standout look.

Your letterman jacket isn’t just an outfit it’s a story, a statement, and a reflection of your pride. So go ahead and design it your way! 

Custom Letterman Jackets: Easy Design Guide

Nothing quite exudes style and timeless charm like a custom varsity jacket. These jackets have held their place in fashion for decades, and their appeal only grows when you add a personal touch. Customization allows you to showcase your personality, turning a classic jacket into something uniquely yours. While a standard varsity jacket is stylish on its own, a custom design takes it to a whole new level. Here’s a simple step-by-step guide to designing your perfect letterman jacket:

Step 1: Choosing the Material and Style of Your Jacket

When planning your varsity jacket, the first and most important step is selecting the right material and style. This decision lays the foundation for the overall look, feel, and durability of your custom jacket. Here’s a breakdown of popular materials for the body of a custom letterman jacket:

Body

Cotton Fleece

Soft, breathable, and hypoallergenic. This fabric is perfect if you have sensitive skin or allergies. Its lightweight comfort makes it an ideal choice for casual wear while keeping you cozy.

Cotton Twill

A thick, sturdy fabric with excellent durability. Cotton twill is perfect if you’re looking for a jacket that’s easy to maintain and built to last. Its classic texture adds a polished, timeless look.

Cowhide Leather

Rugged, durable, and water-resistant. Cowhide leather offers year-round wearability and unmatched comfort. This material is perfect for a jacket that needs to endure the elements while still looking sharp.

Sheep Leather

Smooth, soft, and luxurious. Jackets made from sheep leather exude exclusivity and sophistication. Though pricier, they’re worth the investment for a high-end, elegant look.

Polyester Satin

Silky, soft, and lightweight. The blend of polyester and satin delivers warmth, comfort, and a glossy finish. Ideal if you want a jacket that’s as smooth to the touch as it is eye-catching.

Molten Wool

Thick, durable, and water-resistant. Molten wool is perfect for a robust high school or college jacket that can withstand the elements while keeping you stylish.

Sleeves

When choosing sleeves for your jacket, they are typically made from the same material as the body. However, this doesn’t apply if you opt for Melton wool. In that case, you can select alternatives such as faux leather, cowhide leather, or even sheep leather, which pairs beautifully with Melton wool for a distinctive look.

Style of Sleeves

Set-in Sleeves

This classic style features a visible shoulder seam and runs smoothly along the arm of your jacket. It’s ideal if you want a polished, professional, and formal appearance.

Raglan Sleeves

Raglan sleeves are crafted from a single piece of fabric that extends to the collar, without a shoulder seam. This design creates a looser fit under the arms, giving your jacket a sporty and casual vibe.

Front Closure

Next, you’ll need to decide on the front closure of your jacket. Custom letterman jackets typically come with two options: a zip-up front or a buttoned front. Both are stylish, so your choice depends entirely on your personal taste and the look you want to achieve.

Hood in the Jacket

Did you know that you can add a hood to your custom high school letterman jacket? It’s an optional feature, but if you like the idea, it can give your jacket a modern, casual edge while adding extra functionality.

Knit Styles

The knit pattern appears on the waistband and wristbands of your jacket and plays a big role in its overall aesthetic. There are five popular knit designs to choose from: Plain, Single Line, Single Line with Border, Two Lines, and Two Lines with Border. Pick the one that best complements your jacket’s style.

Inside Lining

For the inside, you have multiple lining options. Choose between quilted lining, which is warm and cozy, or polyester satin, which is strong and durable. If breathability is important, cotton is a great lightweight alternative.

Pro Tip: You can also add a ½ zip-out lining to make adding custom embroidery and patches easier. This prevents loose threads from showing but keep in mind that it doesn’t make the lining removable.

Step 2: Choosing Colors for Your Jacket

As mentioned earlier, most custom letterman jackets feature two main colors. However, you can get creative and incorporate more if you wish though it’s trendy to stick to a maximum of three colors. When it comes to letterman jackets, simplicity often wins.

Start by using the primary colors of your school, organization, or brand as the main color for the jacket’s body. For the sleeves, pick a complementary or secondary color to add contrast and depth. Keep in mind that white sleeves are versatile and pair beautifully with any primary color.

Beyond the body and sleeves, you’ll also need to decide on colors for the smaller details, including:

• Buttons or zipper
• Pockets
• Inner lining
• Knit base, lines, and borders
• Hood

Thoughtful color choices in these areas can make your custom letterman jacket truly stand out.

Step 3: Adding Personalized Designs

Now comes the exciting part turning your jacket into a one-of-a-kind masterpiece. Here, you have full creative freedom to add designs, typography, patches, and badges. Below is a breakdown of the key areas to personalize:

Front Center

The front center is the focal point of any custom varsity jacket. This space is perfect for your name or your organization’s name. You can use up to 12 characters and choose your preferred font style. Additionally, you can decide whether the text is straight or arched, and you can customize the font and border colors to match your jacket’s vibe.

Pockets

Pockets are ideal for smaller patches or letters. You can choose:

• Letters (maximum of 4 characters, embroidered or felt)
• Symbols or custom logos (badges, flags, mascots)

If you upload a logo, make sure it’s high resolution; low-quality images can ruin the final look. Pocket designs should remain relatively small to maintain the jacket’s aesthetic.

Sleeves

Sleeves are great for showcasing your school or college logo, or even your graduation year. Keep it simple too many designs can make the jacket look cluttered. If you want a meaningful keepsake of your school days, your graduation year is ideal. If your goal is to show pride in your institution, the logo works perfectly.

Back Top

This section is often reserved for your name. You can also use a nickname or title if you prefer. While there’s room for creativity, adding your name adds a personal touch and a sense of ownership to your jacket.

Back Middle

The middle of the back is prime real estate for your organization’s mascot. However, you can also place a symbol, logo, or even your name here if it suits your style. This section is flexible and can reflect whatever makes your jacket truly yours.

Back Bottom

Traditionally, this area is used for the name of your team, club, or society. Some students also choose to add a meaningful quote here something that resonates with their personality or values. Use this space to express yourself and make your jacket uniquely memorable. 

Step 4: Selecting the Size of Your Custom Letterman Jackets

This is the final step in your design journey. Once you’ve reached this stage, your varsity jacket is almost ready to wear! Don’t worry there’s no rocket science here. This is simply where you choose the perfect size for your letterman jacket.

From Small and Medium to Large and Extra-Large, sizes are available to fit every body type comfortably. The key is to double-check your measurements getting even a single inch wrong can affect both the fit and comfort of your jacket.

Choosing the right size is especially crucial for group orders, ensuring everyone looks sharp and feels confident in their custom jackets.