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.