Custom Sportswear and Activewear Manufacturer
Nevear makes custom sportswear and activewear for fitness brands, gyms, teams and retailers, from a first run of 50 pieces per style to bulk orders of around 50,000 pieces in a single shipment.
Performance clothing lives or dies on fabric, stretch and seams. Here is what to specify, and how to test a sample before bulk production.
- Minimum order
- Typically 50 pieces per style
- Fabrics
- Nylon or polyester with elastane, mesh, woven stretch
- Branding
- Sublimation, heat transfer, silicone print, embroidery
- Lead time
- Samples 2–3 weeks; bulk 3–4 weeks from order
Activewear we make
- Leggings and bike shorts, high-rise or mid-rise.
- Sports bras and crop tops.
- Gym and running shorts, with or without liners.
- Performance t-shirts and [tank tops](/tank-tops/), and compression tops.
- Yoga sets and matching two-piece sets.
- Track jackets and windbreakers; see also tracksuits.
- Team kits and jerseys, including football jerseys.
Performance fabrics
| Fabric | Properties | Common uses |
|---|---|---|
| Nylon with elastane (often around 20% elastane) | Smooth, soft, strong stretch and recovery | Leggings, sports bras, yoga sets |
| Polyester with elastane | Moisture-wicking and durable; takes sublimation | Training tops, shorts, leggings |
| Lightweight polyester | Quick-drying and breathable | Running tees, team jerseys |
| Recycled polyester or nylon | The same performance from recycled yarn; ask for certified fabric to make the claim | Any of the above |
| Mesh | Ventilation | Back panels, side panels, jersey inserts |
| Woven four-way stretch | Light and packable | Running shorts, joggers, windbreakers |
For leggings, fabric weight and knit density decide how opaque they are. Denser compressive fabrics, often from about 220 GSM up, are more likely to pass a squat test, so test the sample stretched before you approve it.
Construction for movement
- Flatlock seams, which lie flat and do not chafe.
- Coverstitch hems, which stretch with the fabric.
- Gussets in leggings and shorts for freedom of movement.
- Waistbands: high-rise, double layer, internal drawcord or a hidden key pocket.
- Bonded or laser-cut edges for a clean, seam-free finish.
- Reflective details and thumbholes for running pieces.
Branding on activewear
- Sublimation for all-over prints on polyester; works best on light base colors.
- Heat transfers and silicone prints, which flex with stretch fabrics.
- Screen printing with stretch inks.
- Embroidery for small logos on stable areas; it can pucker very stretchy fabric.
- Reflective prints for visibility.
- Jacquard waistbands with your name knitted in.
In close-fitting pieces, printed or heat-transfer labels avoid scratchy neck tags. Add your care and fibre details there.
Test the sample before bulk
- Wear test it through a real workout: running, stretching, lifting.
- Squat test leggings in daylight to check opacity.
- Wash test it several times to check shrinkage, pilling and color.
- Check the seams and waistband for rubbing, rolling and recovery.
Minimums, samples and pricing
Our minimum is typically 50 pieces per style. The exact minimum depends on the fabric and process and is confirmed in your quote; custom-dyed or custom-printed performance fabric can carry its own mill minimum.
The price per piece depends mainly on the fabric, the construction (bonded seams and extra panels add work), the branding method and the quantity. Read what MOQ means, or see how our pricing works.
Tech pack checklist for activewear
- Measurement chart, including waistband height and inseam
- Fabric composition, weight and stretch, plus any mesh panels
- Seam types (flatlock, coverstitch, bonded)
- Waistband, gusset and pocket details
- Colors as Pantone references
- Branding method, size and placement
- Label type (printed or heat-transfer) and packaging
Frequently asked questions
What is the minimum order for custom activewear?
Typically 50 pieces per style. The exact minimum depends on the fabric and production process, and is confirmed in your quote.
Which fabric is best for leggings?
A nylon or polyester knit with elastane, dense enough to stay opaque when stretched. Nylon blends feel smoother and softer; polyester blends wick well and take sublimation prints.
Can you make sublimated team kits?
Yes. Sublimation prints the whole garment and suits polyester team jerseys, shorts and training tops.
Will my leggings be squat-proof?
That depends on the fabric's weight and density. We recommend a squat test on the sample before bulk production, and a denser fabric if it fails.
How long does a sample take?
Samples typically take 2–3 weeks, and the sample cost is stated in your quote. Once you approve the sample, bulk orders are usually delivered 3–4 weeks from the order date, including shipping.
Ready to make your sportswear?
Tell us the style, fabric and quantity. We will confirm the minimum, a sample timeline and the price per piece in your quote.