A bra sheath comprising a sheath-body and a plurality of lugs attached to the inner surface of an elongated liner. The sheath-body and liner define a tunnel for an underwire. A softness layer is disposed adjacent the liner outer surface. The bra sheath is formed by folding the liner and softness layer along the medial line to form a longitudinally extending internal cavity. The liner and sheath-body are comprised of woven fabrics including interlocking warp and weft threads. At least some of the threads are comprised of heat fusible materials that are melted during processing to bond the woven fabric of the liner and sheath-body.

In a first embodiment, a first fabric layer has gelatinous strips, thereby separating the first fabric layer into sections. A second fabric layer is positioned upon the first fabric layer, and an underwire is positioned on the second fabric layer opposite the first fabric layer. The first fabric layer is then folded onto itself to enclose the second fabric layer and the underwire. In a second embodiment, a third, or intermediate, fabric layer is positioned between the first and second fabric layers. In a third embodiment, an underwire is surrounded by a first, non-woven fabric layer. A second, rigid-type fabric having a bladder with a gelatinous material is positioned on the first fabric. The first fabric is wrapped around the underwire, and the bladder is positioned against the body of the wearer.

A cushioned underwire is cooperative with any of a variety of different brassieres having different width and size. The cushioned underwire is adjustable and positioned in a multi-layered casing, which is connected along a perimeter portion of the brassiere. The casing is connected to one or more layers of material used to form a breast cup portion of the brassiere. At least a portion of the casing is overlapped by a cushion and/or protective barrier. This cushion barrier provides both comfort and feminine allure.