Pre-encased underwire assembly

A method of manufacturing an underwire assembly for attachment to other components of a brassiere, the underwire assembly including an inner fabric layer, an outer fabric layer, and an underwire, comprising:

• fastening an outer surface of the inner fabric layer to an inner surface of the outer fabric layer;
• creating a fabric enclosure having a sealed side and first and second open ends by bringing together opposite side ends of an inner surface of the inner fabric layer and fastening the opposite side ends to one another substantially along a length of the fabric enclosure;
• inserting the underwire into the first open end of the fabric enclosure and continuing to pass the underwire through the fabric enclosure until a first end and a second end of the underwire are completely housed within the fabric enclosure;
• and
• sealing the first and second open ends of the fabric enclosure tube such that the underwire is encased within the sealed side and first and second sealed ends of the fabric enclosure.

An underwire assembly for a brassiere comprising:

• an underwire having an inner radius, an outer radius, a first end and a second end;
• a fabric enclosure having a sealed side, a first sealed end and a second sealed end;
• a first fabric extension extending outwardly from the first sealed end of the fabric enclosure;
• and
• a second fabric extension extending outwardly from the second sealed end of the fabric enclosure,
• wherein when the underwire is completely housed within the fabric enclosure the outer radius of the underwire is adjacent the sealed side of the fabric enclosure, the first end of the underwire is adjacent the first sealed end of the fabric enclosure, and the second end of the underwire is adjacent the second sealed end of the fabric enclosure.