This is making me wonder: do you think they could just replicate clothes to be perfectly interwoven so that there are no seams? Different fabrics could just be perfectly bonded to each other with no stitching required, and the fabric itself woven in the correct shapes instead of flat fabric needing to be cut and stitched together like we do.
You made me think about this longer than I'd care to admit, and I've come to the conclusion that yes, but.
You'd lose the ability to create certain styles. Sometimes you need to bunch up fabric on one side of a stitch, and it's only secured by the stitch itself. Sometimes you need sharp corners that require a seam. Think about your pockets. Without some clever joinery, your pockets are just kinda poofs.
Sometimes you need to build up material to add some strength and just sticking more fibers together won't last as long.
If every individual thread forms a perfect, closed loop and is intertwined with all the others, that works. But you kind of dress everyone in sweaters only.
If we're talking in universe, this takes place before replicators that would allow for your concept. Still, there ought to be a better means for fabrication. In the meantime, it serves as a callback to 60's cone bras.
Wasn't there a scene in Discovery where Burnham replicated a uniform and they showed it on the microscopic level with fancy cgi? Maybe they had the ability to replicate some simpler things?