Darn Right: Socks Made in USA

Various brands write "Made in the USA" with varied meanings and standards. So, you might wonder about the significance of our promise: “Still Made in Vermont, USA.”

When asked, our President & CEO Ric Cabot, leadership staff, and Mill employees all emphasized the importance of Darn Tough’s commitment to manufacturing in the U.S. and the positive ripple effects on ethical labor standards, community investment, and social responsibilities.

These are all important byproducts of manufacturing in the U.S., but their meaning is more.

How It Began: Socks Made in America from Day 1

In 2004, most previously-USA sock manufacturers had moved production overseas. Nearing bankruptcy, Cabot Hosiery Mills in Northfield, Vermont, felt the pressure to do the same.

When businesses leave, the holes left behind are more than just holes in the ground. “There's a bigger impact,” said Ric, “around the people and communities we'd been serving for close to 50 years.” So, Ric and his father Marc held firm to USA made socks.

Ric Cabot firmly believed he had the key to keeping manufacturing in Vermont. At 25, Ric, the third generation in his family’s sock business, envisioned a premium sock brand offering an industry-first lifetime guarantee. Ric and his family invested personal equity, and with that bold vision, Darn Tough was born.

“We wanted to do it ourselves,” he said, “and we had the skilled workforce to make it happen; plus, pride and a bit of ego.”

Ric stated that the driving forces behind keeping ownership of the Mill and sock production in Vermont were “generational history and a drive to make a best-in-class product locally. Our folks rallied around the vision and promise of Darn Tough to make it happen.” 

Now, 400 U.S.-based employees form the foundation of Darn Tough’s mission to make the best socks in the world, right here in Vermont.

From Concept to Creation: Designing & Knitting Made in the USA Socks

So, what does it mean that all Darn Tough socks are still made in Vermont, USA?

All the knitting, washing, drying, finishing, and packaging behind these USA made wool socks occurs in Vermont Mills, run by Vermonters. And we've never done it any other way.

Each of these Vermont made sock’s journey — from raw materials to the finished product — weaves a story of quality and attention to detail.

Design & Testing

Each sock’s conception begins in Vermont, where our Product team engages in in-depth research, development, and design. They innovate and refine. They conduct real-world testing to ensure the socks excel in all conditions, whether on Vermont’s rugged hills and mountains or at job sites across the country.

The company’s commitment to in-house research, design, and development combines a culture of education and innovation with an indefinite desire to improve, to create the best American made socks.

Sourcing & Knitting

We select only the finest, premium Merino Wool, nylon, and spandex yarns for use. In order to meet demand and our strict durability standards, we source the highest quality yarns from sheep in Australia, New Zealand, South America, South Africa, and the U.S. 

Because we are the Mill, we can control quality at every step of the sock-making process. Knitters, line supervisors, material handlers, sample operators, and machine technicians are just a few of the roles that craft each pair of Darn Tough socks in Vermont.

Darn Tough's manufacturing blends modern technology with traditional craftsmanship. Advanced knitting machinery ensures consistency and efficiency, while careful supervision and manual packaging emphasize quality and artisanal care.

Once yarns arrive at the Mill, they are prepared and fed into specialized knitting machines. These state-of-the-art machines can produce complex patterns and precise elasticities. The machines knit each sock, one at a time, while knitters closely monitor the machines to ensure proper tension, stitch count, and pattern accuracy. This meticulous process produces socks that are durable and comfortable.

Finishing & Packaging

After the socks are knit, employees examine the fabric for imperfections, ensuring that only perfectly crafted pairs of socks move forward in the process. Any socks that do not meet their stringent standards are carefully set aside for recycling, donation, or another purpose. 

Socks then continue to the finishing, labeling, and packaging phase. Machine-knit socks are washed and dried, then manually stretched and measured by Mill employees.

Employees fold the finished socks into the packaging. This manual handling provides an added layer of quality assurance and an opportunity to verify that the two socks in each pair match in size, color, and pattern.

Quality, Control, Research, & Design

Darn Tough’s International Sales Manager Joe Nocito said, “When it comes to quality control, research and design, the ability to design, knit, and repeatedly test samples until we are satisfied, yet retain an insatiable desire to make better socks, is paramount to our success.”

Our Product team and knitting machines work under the same roof, making collaboration seamless (like our socks).

“I'm honored to bring our Vermont socks around the world,” said Joe, “I find it incredibly rewarding to see our products embraced by customers thousands of miles away from home. Each time I introduce myself to a new customer and share the story of our socks, I emphasize that I know the people who made them.”

This personal connection is at the core of who we are: when you buy Darn Tough, you’re not just purchasing a Vermont wool sock; you’re also investing in quality craftsmanship rooted in family, friendship, and local community.

Our Tactical Socks: 100% US-Sourced & Made

In accordance with the Berry Amendment, Darn Tough's Tactical socks are crafted with 100% US-sourced materials and meet the highest standards for military and tactical use. One of the most significant challenges is sourcing American wool that meets our high-quality standards.

Our Tactical socks offer unmatched durability, comfort, and performance in demanding environments. Because they are Berry Compliant (sourced and produced domestically), these styles are prioritized to supply the military first, which can make them less available to the public.

We Know the People

To Joe, local manufacturing is valuable for multiple reasons. “If we were manufacturing with factories overseas,” he said, “we wouldn't know the people making our socks.”

Darn Tough can confidently back its socks with a Lifetime Guarantee because the owners are on the floor where each sock is made. Joe compared walking through Darn Tough's Mills in Vermont to Willy Wonka's Chocolate Factory. But for socks.

Local manufacturing means that everyone involved is close to the process, and anyone from the Vermont-based team can be on the knitting room floor within minutes.

Labor Practices

By keeping manufacturing within the U.S., Darn Tough can ensure that its production standards align with ethical labor practices, which can often be challenging to verify in countries with less stringent regulations.

Each employee we spoke with values how Darn Tough's owners give and care about employees: competitive pay, benefits, training, and opportunities for advancement. The fact that 395 of our employees live in Vermont speaks to the company’s dedication to hiring locally, commitment to community engagement, and prioritization of local investment.

Production Machine Technician Apprentice Anita Dimento, who has been with the company for four years, said, “We see the owners often, which is nice. It feels like they listen and care. If manufacturing were overseas,” she said, “I think it would be very hands-off and not as involved in every step of the process.”

Finishing Team member Felicia Brocar, who has been with the company for three years, said, “Marc and Ric Cabot, and my supervisors and managers, don't treat us just as a number or worker. They care about you and how you're doing mentally and physically. They’re always checking in with all of us, making sure we're doing well, making sure that we have what we need. And that's what I really appreciate about this company: they care about us as a whole person.”

Why Local Production Matters

Darn Tough’s commitment to U.S.-based manufacturing underpins everything we do. This dedication helps maintain the manufacturing skills that might otherwise be lost to overseas production, ensuring a legacy of craftsmanship and quality that helps future generations.

Global Director, Environmental and Social Responsibility, Kristen Graf said, “Owning our manufacturing allows us to have much more direct control over many environmental and social aspects of our product as opposed to being a brand that outsources much of the manufacturing.”

In contrast to the vast quantity of socks imported to the U.S. from countries like China, where production costs are lower, Darn Tough’s local operations keep the economic benefits close to home. For instance, the Wall Street Journal reported that in 2023, China alone accounted for a staggering 56% of sock and stocking imports to the U.S.

Environmental Responsibility & Customer Responsiveness

Vermont’s commitment to renewable energy provides a favorable setting for the our manufacturing operations. By controlling the entire manufacturing process and sourcing materials ethically, we can more effectively manage our environmental responsibilities, ensuring our practices align with sustainable values.

Moreover, our ownership of manufacturing operations allows us to promptly respond to customer feedback and innovate based on immediate needs.

For example, thanks to product testing and consumer feedback, we have made significant durability updates to our Run sock category, created the first sock specifically engineered for steel-toed boots, and are actively growing and improving the technology behind Snow socks. 

On the other hand, the ability to track and adapt, and respond quickly to consumer preferences, is often diminished, if not lost, in outsourced manufacturing, where communication and response times can be prolonged and inefficient.

Reinforcing Community Investment

Darn Tough creates local jobs that support Vermont residents and businesses. When employees spend their earnings locally, the company contributes to community vitality. This in-state investment is further amplified through initiatives like the Knit to Give program and sock donations to shelters and charities.

Knitter Ash Barcomb (they/them) said, “One of the best things about working here is that it isn't just a place where you come to work every day. People care about your voice and opinions, and there's a lot of talent here. Anywhere you walk in here [at the Mill], you'll find somebody with an amazing skill.” Including Ash.

The same year they began working for Darn Tough, we started an employee sock design contest. Ash won twice. Ash said, “It was a great opportunity to come outta my shell. I’m an artist outside work, so I appreciate the chance to show that here.”

People First, Product Second

Darn Tough's journey highlights the importance of U.S. manufacturing for economic, social, environmental reasons, and stewardship. Ric and Marc Cabot’s decision to maintain ownership of the Mill and keep production in Vermont stemmed from a steadfast commitment to the people and communities they serve.

In an age when the global supply chain is often leveraged for cost savings, Ric Cabot says that manufacturing locally is not merely a business decision but a moral imperative.

Darn Right: When Actions Back Words

“If you're really serious about something, you make it yourself,” said Ric Cabot. So, that is what we do. We're on a mission to create the best socks, made in USA, and back them with an unconditional Lifetime Guarantee.

That’s the meaning of manufacturing in the U.S., and perhaps uniquely, to manufacturing in Vermont for Darn Tough: Pride in your workers, commitment to your customers, dedication to an economy in which individuals and companies thrive, and ownership of process and quality so we can create the best Merino Wool socks made in the USA.

Be responsible and accountable. Own the final product. Take the tougher road.

We did; we still do.