OEM & ODM
Change the size, the panel, the cover, the print, the pack
Five levers. Most custom ball projects only need two of them, and the other three are where the cost quietly runs away. We quote them separately so you can see which one is expensive.
1. Size
Every ball family has a standard ladder, and every ladder has a diameter. Match the diameter to the market, not to the habit.
| Ball | Size 1 | Size 2 | Size 3 | Size 4 | Size 5 | Size 6 | Size 7 |
|---|---|---|---|---|---|---|---|
| Soccer (diameter) | 130 mm | 150 mm | 180 mm | 190 mm | 210 mm | — | — |
| Basketball (diameter) | 127 mm | 160 mm | 180 mm | 200 mm | 220 mm | 226 mm | 246 mm |
| Volleyball (diameter) | — | 150 mm | 180 mm | 194 mm | 214 mm | — | — |
| American football (length) | — | — | 216 mm | — | — | 270 mm | — |
| Rugby (length) | 150 mm | 220 mm | 260 mm | 275 mm | 300 mm | — | — |
| Playground (diameter) | 120 mm | 150 mm | 175 mm | 212 mm | — | — | — |
2. Panels
Soccer balls come in 6, 12, 14 and 32 panel builds. Panel count changes flight stability and print cost in opposite directions: 32 panels curve truer, 6 panels print bigger artwork for less money. A 32-panel ball at the same weight will feel firmer because the seams add structure.
Basketball and volleyball use 8 and 18 panel conventions. Changing those is possible but rarely worth it — players notice.
3. Cover and thickness
| Construction | Cover options | Thickness | Where it belongs |
|---|---|---|---|
| Soccer, machine stitched | PVC, PU, TPU, neoprene, EVA | 1.6–4.0 mm | School and club volume |
| Soccer, thermal bonded | PU, PU + rubber backing | 3.5–4.0 mm | Wet climates, match use |
| Basketball, laminated | PU, TPU, PVC, microfiber | 1.0–1.6 mm | Indoor, retail pack |
| Basketball, rubber | Rubber compound | Moulded | Outdoor courts |
| Volleyball | PVC, PU, laminated film, rubber | 1.6–2.5 mm | Indoor, beach, school |
The cheapest change with the biggest effect is going from 1.6 mm to 2.7 mm PVC. It adds about 90 g to a size 5 and roughly doubles the expected service life on abrasive surfaces.
4. Print and logo
- Pad print — one to four colours, lowest tooling, best for small logos on rubber balls.
- Heat transfer — full colour, sharper detail, slightly higher unit cost.
- Laminated film — photographic graphics with no seam interruption; the retail standard.
- Moulded-in — graphics formed into the cover itself, so nothing wears off. Best on PVC, PU and rubber.
Send vector artwork with Pantone references. We return a panel layout proof before cutting anything, because a logo that crosses a seam at the wrong angle is the most common reprint cause we see.
5. Packaging
| Format | Best for | Note |
|---|---|---|
| Deflated, OPP bag | Container volume orders | Cheapest per CBM, needs a pump at destination |
| Blister | Retail shelf | Available on soccer, basketball and volleyball |
| PDQ display tray | Counter display | Holds 6–12 units, ships inside the master carton |
| MG tissue paper | Gift and premium | Wraps the ball, adds perceived value at low cost |
Private label is a carton artwork exercise, not a moulding one. Barcodes, warning text and country of origin all go on the master carton and the inner pack, and we proof both.
Send the five levers
Size, panel, cover, print, pack. With those we can quote without a second email.