Folks have been asking us how our Popcorn Shirts are made since the beginning of time.
We're happy to be able to show you the process from start to finish.

The fabric for Popcorn Shirts is spread out on a table in multiple layers.

The shirt pieces are cut out using an industrial fabric saw to cut through the multiple layers of fabric. 
The shirts start out many sizes bigger than they will end up.

The shirt pieces are then sewn together to become very large shirts.

 

Each shirt is hand "popcorned" using one continuous thread to hold all of the puckers in place.
That one thread is looped from pucker to pucker all around the entire shirt. 

A custom tool is used to assure uniformity from shirt to shirt.   

The popcorned shirts are placed in a cradle. Look closely and you'll see dozens of shirts here.  

The cradle is covered and then slid into a steamer.

High temperature and steam create permanent popcorning.

The shirts are then soaked in a solution bath to cure the popcorning in place.

All of the moisture from the steam and bath are removed by spinning at a high rate of speed.

Then the shirts are dried in an industrial dryer customized for Popcorn Shirts.

The single thread that holds the popcorn in place is then removed by pulling it until the popcorning is fully released.

After the shirts are inspected, they are packed into boxes for shipment to The Magic Scarf Company.