These are the foam pads about to become chamoix. The pads are uniformly heated and then cut in a special oven. Many manufacturers use a hot plate to form the pads, which leaves tough edges and differing foam densities. Giordana's method creates a soft and even pad without seams. Fresh chamoix, hot off the press.
This ink will be mixed to create every possible color for team kit designs.
A kit design is printed on the giant ink jet, ready for transferring.Screens are made for each color, and then the screens are used to layer one color at a time onto the jersey fabric.
Giorgio holds up an almost completed AC skinsuit. For all of you who've asked when we're getting new kits in, the answer is: soon!
Next door to the Giordana factory is the DMT shoe factory. We saw the foot-lasts of some well-known athletes...Now that Mr. Armstrong has switched to jogging, these can probably get pitched.
Part 3 will follow shortly!