Abstract: A method for producing a permanently pleated garment is disclosed, whereby pleat formation is achieved during subassembly before the garment is finished by positioning a subassembly with a pre-pressed pleat on a vacuum device having a conforming pleat groove, exerting a vacuum on the subassembly and on a pleat formed within the subassembly, maintaining a vacuum on the garment subassembly and the pleat, dispensing a sufficient amount of polymeric dispersion along the pleat while maintaining the vacuum, and folding and removing the subassembly from the vacuum device, followed by curing of the polymeric dispersion and incorporation of the subassembly in a finished garment.