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What is different about making stretch performance clothing, and what to specify and ask before you place an order.
Activewear looks simple, but it is one of the more technical categories to make. The fabrics stretch and recover, the seams sit against the skin and the garments are judged on how they feel and perform during movement. That changes how you choose fabric, write your tech pack, fit samples and choose a factory. This guide covers what is different. For the general process, start with how to start a clothing line.
Yoga, running, gym training, cycling and outdoor sport each make different demands on fabric, seams and fit. Decide the main use, the support or compression you want and the price level, because these drive every later choice.
Activewear fabrics are usually knits made from synthetic fibers, such as polyester or nylon, often blended with elastane (also sold as spandex or Lycra) for stretch. Compare weight, how far the fabric stretches, how well it recovers its shape, how it feels, whether it is opaque when stretched and whether it has a moisture-management or other finish. Ask for swatches and test them. See how to choose fabric and our answer on Lycra, spandex and elastane.
Seams matter more in activewear because they rub against the skin. Many brands use flat, low-profile seams, such as flatlock or coverstitch, and keep seams away from high-friction areas. Think through the waistband, gusset, pockets, drawcords, reflective details and any bonded or welded seams. Each one needs a clear spec.
Stretch changes how you measure. State whether each measurement is taken relaxed or stretched, give tolerances, and specify the stitch types, the thread, the elastic and any trims. Add the stretch and recovery you expect from the fabric. Our tech pack guide and the free Tech Pack Template help you structure it.
Fit-test on a model who moves: squat, lunge, bend and reach. Check that the fabric does not become see-through when stretched, that waistbands stay put and that seams do not chafe. Run wash tests for shrinkage, color change and pilling. Use the fit session guide and the Fit Comment Form.
Look for factories with experience in stretch knits, coverstitch and flatlock machines and printing methods such as sublimation if you need them. Ask what fabrics they source or accept, their minimums for fabric and for each color, and whether they have made similar garments.
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Fabric minimums often set the size of your first order. Cost each style, compare quotes and plan the production schedule.
Use the Garment Cost Sheet, Supplier Quote Comparison and Production Timeline Planner.
Most activewear is knit from synthetic fibers such as polyester or nylon, often blended with elastane for stretch. Some uses call for natural or blended fibers, so choose by performance, feel and price.
Stretching a fabric spreads its fibers and can reveal skin. Test opacity with the fabric stretched, and fit-test on a person who squats and bends before you approve it.
Flat, low-profile seams, such as flatlock and coverstitch, are common because they sit comfortably against the skin. The right choice depends on the garment and the factory's equipment.
State in the tech pack whether each measurement is taken relaxed or stretched, and give a tolerance. Agree the method with the factory.
Browse the Apparel Search directory of activewear, legging and fitness clothing factories, then ask for samples and references before you commit.