The purpose of the study was to investigate the challenges of manual pattern making and propose solutions in garment sector of micro and small enterprises (MSEs) of Bahir Dar City in Amhara Regional state of Ethiopia. Descriptive survey method was employed for investigating the challenges. Furthermore, the assessment of challenges was supported by the Driving forces, Pressures, States, Impacts and Responses (DPSIR) framework. A total of 55 respondents (45 MSEs and 10 trainers) were selected using random sampling technique. The study revealed that lack of skills and training, low awareness on the benefit of patterns, lack of pattern making tools, and lack of the availability of measurement chart as challenges in manual pattern making. The lack of pattern making skills was found to be the major challenge in MSEs. Men’s shirt was produced using manual pattern making as a porotype and compared with men’s shirt produced by MSEs using free hand cutting. The quality and cost of the porotype were found to be better than the men’s shirt made without pattern. Recommendations made are: TVET trainers should give training by first performing a training need assessment survey; TVET trainers should be responsible for the transfer of knowledge to MSEs with regard to use of different pattern making tools; there has to be increased availability of appropriate training materials on manual pattern making (e.g. Amahric pattern making manual). Key words Pattern making, Patterns, skill gaps, demand.