Football shirts have changed enormously over the years. What started as a relatively simple way of distinguishing one team from another has developed into a highly technical piece of sportswear and, for many supporters, a fashion statement and collectable.

Modern shirts worn by professional footballers are designed to be lightweight, breathable and comfortable while coping with 90 minutes of running, tackling, stretching and, occasionally, being pulled by an opponent.

But how does a football shirt go from an idea on a designer’s screen to the shirt worn by thousands of supporters?

1. Designing a Football Shirt Can Start Years Before You See It

One of the most interesting things about football shirts is just how far in advance they can be planned.

Major sportswear manufacturers and football clubs don’t simply wait until the end of the season before deciding what next year’s shirt will look like. The design and production process can begin well ahead of the official launch.

Designers need to consider the club’s traditional colours, previous kits, sponsor requirements, manufacturer branding and current fashion trends.

There is also the difficult balancing act of creating something new without upsetting supporters. This is often why some fans buy mystery shirts; learn more on the Football24-7 website, which is dedicated to these shirts.

Change a famous shirt too much, and fans may complain that it no longer looks like their club. Change too little, and people may question why they should buy the new version.

2. The Colours Aren’t Always as Simple as They Look

You might think creating a red, blue or green football shirt would be straightforward.

It isn’t necessarily.

Manufacturers need colours to remain consistent across thousands or even millions of shirts produced in different sizes and sometimes at different manufacturing facilities.

A club’s particular shade of red or blue can form an important part of its identity.

Designers therefore work with precise colour specifications rather than simply asking the factory to make a shirt “blue”.

The challenge becomes even greater when a shirt includes gradients, patterns, stripes or graphics.

3. Modern Shirts Are Usually Made from Polyester

Pick up a modern football shirt, and there’s a good chance that most of it is made from polyester.

There is a good reason for that.

Polyester can be manufactured into lightweight material that dries relatively quickly and is suitable for producing sports clothing.

Manufacturers can also engineer the fabric in different ways to improve ventilation and moisture management.

This is a world away from the heavy shirts worn by footballers during the early years of the game.

Imagine playing 90 minutes in a thick cotton shirt on a wet Saturday afternoon.

Once those early shirts absorbed rain and sweat, they could become considerably heavier.

Today’s players don’t have quite the same problem.

4. Some Football Shirts Begin Life as Plastic Bottles

Sustainability has become increasingly important within sportswear manufacturing.

Several major manufacturers now produce football clothing made from recycled polyester, which can be derived from materials such as plastic bottles.

The plastic is cleaned and processed before being transformed into material that can eventually become polyester fibres.

Those fibres can then be turned into fabric.

It means something that may once have been considered waste can potentially end up being worn by a Premier League footballer.

5. Those Tiny Holes Have a Purpose

Look closely at a modern player shirt, and you’ll often notice tiny perforations, mesh sections or areas where the fabric construction appears different.

They’re not simply decorative.

Manufacturers analyse areas of the body where footballers generate significant heat and sweat.

Different fabric structures can then be positioned around areas such as the back, sides and underarms to improve airflow and help manage moisture.

The result is effectively a shirt with different performance zones.

It might look like one simple piece of clothing from the stands, but considerably more engineering can be involved.

6. The Pattern Might Not Be Printed Onto the Finished Shirt

One technique commonly used when producing sportswear is dye sublimation.

Instead of simply applying a thick layer of ink to the surface, sublimation allows a design to become part of polyester fabric through a combination of specialist inks and heat.

The design is initially printed onto transfer material.

Heat and pressure are then used to transfer the design into the polyester fibres.

This can be particularly useful for detailed patterns, gradients and graphics because the finished design doesn’t behave like a heavy layer of conventional printing sitting on top of the material.

7. Badges Can Be More Complicated Than You Think

The club badge is one of the most important parts of any football shirt.

Traditionally, badges were often embroidered.

Embroidery still exists, particularly on certain replica or retro-style shirts, but manufacturers also use heat-applied and lightweight badges.

Why?

Weight matters when you’re designing elite sportswear.

A traditional embroidered badge contains thousands of individual stitches. A modern lightweight crest can potentially provide the same visual identity while weighing less and sitting flatter against the shirt.

To a supporter, the difference may appear tiny.

To a sportswear engineer trying to remove unnecessary grams from a player’s kit, everything counts.

8. Player Shirts and Supporter Shirts Can Be Different

This is something that occasionally causes confusion among supporters.

The shirt worn by a Premier League player on the pitch may not be identical to the standard replica version hanging in a club shop.

Manufacturers frequently produce different versions.

An elite or “authentic” shirt is generally designed specifically with performance in mind. It may feature lighter materials, a more athletic fit and additional ventilation technology.

Replica shirts are normally designed to provide greater everyday comfort and durability.

That’s why two shirts that appear almost identical can feel surprisingly different when you actually wear them.

It can also explain some of the difference in price.

9. Sponsors Aren’t Necessarily Sewn Onto the Shirt

Sponsors have become such a familiar part of football shirts that it is difficult to imagine many modern kits without them.

However, the sponsor logo is often applied separately rather than being part of the basic fabric construction.

Heat-transfer technology can be used to apply sponsor graphics, sleeve patches, competition badges, player names and numbers.

This also allows shirts to be customised relatively late in the process.

A blank shirt can effectively become a particular player’s shirt once the correct name, number and competition patches have been added.

10. Shirts Have to Survive More Than One Match

Before a football shirt reaches the pitch or club shop, manufacturers need to consider considerably more than its appearance.

Materials can be tested for properties such as stretching, colour durability, washing and general wear.

Think about what happens during a match.

A shirt can be soaked in sweat, pulled by another player, stretched during tackles and exposed to rain, mud and grass.

It still needs to maintain its basic shape and appearance.

Replica shirts face a different challenge: repeatedly surviving the washing machine.

11. Tiny Differences Can Make Certain Shirts Collectable

Football shirt collectors pay enormous attention to details.

A slightly different sponsor, competition patch, manufacturer logo or even printing style can turn what appears to be an ordinary shirt into something much more interesting.

Match-worn shirts are particularly fascinating because they may contain details not found on standard retail versions.

Depending on the club, competition and era, these differences might include different lettering, patches, internal labels, sizing, ventilation panels or shirt construction.

This is one reason authentication has become such an important part of football shirt collecting.

Why Do Clubs Release So Many Football Shirts?

Traditionally, supporters mainly expected a home shirt and an away shirt.

Today, a major club might release a home kit, away kit, third kit, goalkeeper kits, special editions, anniversary shirts, training collections and retro ranges.

There is obviously a commercial reason for this, but football shirts have also moved beyond the stadium.

Retro shirts in particular have become part of mainstream fashion.

A classic 1990s football shirt can now be worn with jeans or trainers by someone who has absolutely no intention of playing football.

That crossover between sport, nostalgia and fashion has helped turn football shirts into a huge collecting culture.

Interesting Football Shirt FAQs

How long does it take to design a football shirt?

The development process can begin well before supporters see the finished kit. Manufacturers have to allow time for designing, testing, club approval, sponsor integration, manufacturing and distribution. For major clubs producing large quantities of shirts, considerable advance planning is required.

What are football shirts made from?

Most modern football shirts are predominantly made from polyester. Manufacturers use different constructions and technologies to make the material lightweight, breathable and suitable for sport.

Are football shirts made from recycled plastic bottles?

Some modern football kits use recycled polyester made from recycled plastic, including plastic bottles. The exact recycled content varies between manufacturers and individual products.

Are the shirts players wear different from replica shirts?

They can be. Many manufacturers sell both authentic or player-specification shirts and standard replica versions. Player versions are generally lighter, more fitted and focused on performance, while replica shirts are designed with everyday supporters in mind.

Why are authentic football shirts more expensive?

Authentic versions can use more advanced fabrics, lighter components and more complex manufacturing techniques. They are designed to replicate more closely the shirts supplied to professional players.

Are football badges embroidered?

Some are, but not all. Modern shirts increasingly use lightweight heat-applied or engineered crests. Retro and replica shirts may still feature traditional embroidered badges.

How are football shirt names and numbers added?

Names and numbers are commonly applied using specialist heat-transfer equipment. Clubs and retailers can therefore personalise shirts after the main garment has been manufactured.

Why do football shirts have tiny holes in them?

Small perforations and mesh-like sections can improve ventilation. Manufacturers often position breathable areas around parts of the body where players generate more heat.

Why do old football shirts feel heavier?

Older shirts were often produced using heavier materials. Modern synthetic fabrics have enabled manufacturers to make football kits significantly lighter and more moisture-resistant.

What makes an old football shirt valuable?

Age alone doesn’t determine value. Rarity, condition, player association, unusual sponsors, limited production runs and whether a shirt was match-issued or match-worn can all influence collector interest.

Premier League Football Shirts and Club Merchandise

Football shirts may be the most recognisable piece of club merchandise, but they are now only one part of a much bigger market.

Premier League clubs have developed extensive merchandise collections covering everything from replica kits and training clothing to retro shirts, jackets, scarves, hats, gifts and collectables. The official Premier League shop itself now separates merchandise into clothing, accessories, footballs and other categories.

For supporters, merchandise provides another way of showing their connection to a club. For collectors, meanwhile, older shirts and unusual products can become fascinating pieces of football history.

Arsenal Shirts and Merchandise

Arsenal’s famous red and white colours have produced some instantly recognisable football shirts.

Alongside current home, away and third shirts, Arsenal merchandise extends into training clothing, leisurewear, jackets, scarves, hats and accessories.

Retro Arsenal shirts are particularly interesting for collectors. Designs associated with different periods of the club’s history can instantly bring back memories of particular players and seasons.

The club’s shirts also demonstrate how manufacturers can introduce new patterns and details while retaining the traditional colours supporters expect from an Arsenal home kit.

Arsenal’s latest shirts are included among the official Premier League’s 2026/27 kit releases. Check out the Arsenal Football24-7 memorabilia here

Liverpool Shirts and Merchandise

Few football colours are as closely associated with a club as Liverpool and red.

Liverpool merchandise naturally places the famous red shirt at the centre of its collection, but supporters can also find away and third shirts, training clothing, tracksuits, jackets, scarves, hats and numerous accessories.

Liverpool is also a particularly interesting club for retro football shirt collectors.

Shirts associated with different periods can be distinguished by changes to manufacturers, sponsors, collars, patterns and the presentation of the Liverpool badge.

The 2026/27 collection provides another example of football looking backwards for inspiration, with Liverpool’s current designs drawing comparisons with classic shirts from the late 1980s and early 1990s. Check out the Liverpool Football24-7 memorabilia here

Manchester United Shirts and Merchandise

Manchester United has one of football’s most recognisable merchandise ranges.

The red home shirt remains at its heart, but the modern United range goes considerably further.

The club’s current official store includes home and away kits, goalkeeper clothing, training wear, pre-match products and adidas Originals merchandise. There are also adult, women’s and children’s versions of many products.

One interesting area is shirt personalisation.

Supporters can purchase shirts carrying player names and numbers, while competition badges and different printing options can further change the appearance of a shirt.

Manchester United also has an enormous back catalogue of memorable designs, making retro United shirts an important part of football shirt culture. Check out the Manchester United  Football24-7 memorabilia here

Chelsea Shirts and Merchandise

Chelsea’s royal blue home shirt gives the club a strong visual identity, but away and third kits have allowed designers considerably more freedom over the years.

That has resulted in Chelsea shirts appearing in numerous colours and styles.

The club’s 2026/27 home shirt provides an interesting example of how modern manufacturers can combine a relatively clean design with retro influences.

Beyond shirts, Chelsea merchandise encompasses the wider world of modern football fashion, including training wear, jackets, leisurewear and supporter accessories.

Older Chelsea shirts can be especially interesting because changes in sponsors and manufacturers make it relatively easy to associate particular designs with different periods of the club’s history. Check out the Chelsea FC Football24-7 memorabilia here

Tottenham Hotspur Shirts and Merchandise

Tottenham’s traditional white home shirt is another example of the challenge facing football kit designers.

How do you reinvent something that supporters expect to remain predominantly white?

The answer is often found in the details.

Different shades of navy, collar designs, sleeve patterns, trims and subtle graphics allow manufacturers to create a new Tottenham shirt without losing the identity of the traditional Spurs kit.

Tottenham merchandise also includes away and third shirts, training wear, jackets, tracksuits and everyday supporter clothing.

Retro Spurs shirts are another popular area for collectors, particularly designs associated with famous cup runs, European campaigns and memorable players. Check out the Tottenham FC Football24-7 memorabilia here

Brighton & Hove Albion Shirts and Merchandise

Brighton’s blue and white stripes make the club’s home shirts immediately recognisable.

Striped shirts present designers with an interesting challenge because there are only so many ways to change the basic concept without straying too far from the club’s traditional appearance.

Manufacturers can experiment with stripe width, shades of blue, sleeves, collars, and additional patterns.

Away and third shirts provide considerably more freedom and can introduce colours that would never normally appear on a Brighton home kit.

Brighton merchandise has also expanded alongside the club’s growing Premier League profile, with shirts forming part of a broader range of supporter clothing, training wear and accessories.

Brighton & Hove Albion’s latest kit is included in the Premier League’s official collection of 2026/27 club shirts.  Check out the Brighton Football24-7 memorabilia here

Football Merchandise Is About More Than the Current Season

Perhaps the most interesting development in football merchandise is that supporters don’t necessarily want the newest product.

A fan might walk into a stadium wearing the current home shirt while the person sitting next to them is wearing a design from 1994.

That is relatively unusual in sport and demonstrates the emotional connection supporters have with football shirts.

Older shirts can represent childhood, a favourite player, a promotion season, a cup final or simply a memorable period supporting the club.

Manufacturers and clubs have recognised this enthusiasm, which is why retro-inspired clothing and reissued designs have become an increasingly visible part of football merchandise.

It has helped transform the football shirt from something worn primarily on matchday into something that sits somewhere between sportswear, fashion, memorabilia and football history.

And that may explain why supporters’ wardrobes keep filling up with them.

From Team Colours to Technical Sportswear

The next time you pull on your team’s shirt, it is worth taking a closer look.

Check the inside of the badge. Look at how the sponsor has been applied. Hold the material up to the light and examine the ventilation. Compare an authentic shirt with a standard replica.

What appears to be a relatively simple piece of polyester is actually the result of design, textile engineering, printing, branding and manufacturing.

And perhaps that’s part of what makes football shirts so interesting.

They aren’t simply something used to tell two teams apart.

They represent the club, the manufacturer, the technology and fashion of a particular period. Years later, one glance at an old shirt can immediately take a supporter back to a famous player, a memorable match or an unforgettable season.

For many football fans, that’s why a football shirt will always be much more than just a shirt.