Custom Activewear Manufacturer in Los Angeles

The most common activewear fabrics are nylon/spandex blends (typically 80/20 or 75/25) and polyester/spandex blends. Nylon has a softer hand feel and higher stretch recovery. Polyester is more durable, dries faster, and is required for sublimation printing. Fabric weight typically ranges from 200–280 GSM for leggings and 140–180 GSM for tops.

Four-way stretch means the fabric stretches both horizontally and vertically. The spandex content (typically 15–25%) determines the stretch percentage and recovery rate. Higher spandex = more stretch and better shape retention. Two-way stretch only stretches in one direction and is not suitable for performance activewear where full range of motion is required.

Flatlock seaming creates a flat, smooth seam that lies flush against the skin. Standard overlocked seams create a raised ridge that causes chafing during exercise. Flatlock uses a specific machine (flatlock or coverstitch) that interlocks the fabric edges without stacking them. It is essential for leggings, sports bras, compression garments, and any piece worn against the skin during movement. Learn more about construction methods in our cut and sew manufacturing guide.

Yes, but sublimation requires 100% polyester or polyester-dominant fabric (minimum 85% polyester). The process uses heat and pressure to turn ink into a gas that bonds permanently with polyester fibers. It produces vibrant, all-over prints that will not crack, peel, or fade. Sublimation does not work on nylon, cotton, or dark-colored fabrics.

Our minimum is 100 pieces per style per colorway. Activewear requires higher MOQs than basic apparel because the fabrics are more expensive, sewing operations are more complex (flatlock, bonded hems, gusseted crotch), and quality testing (stretch recovery, pilling, moisture management) adds production steps. See how MOQs work across different garment types in our MOQ guide for clothing brands.

We test for moisture-wicking speed (how quickly sweat moves from skin to fabric surface), pilling resistance (Martindale abrasion test — minimum 20,000 cycles for activewear), colorfastness to sweat and washing (ISO 105 standards), stretch recovery (fabric returns to original shape after 50+ stretch cycles), and UPF rating for outdoor athletic wear.

Yes. We produce sports bras (light, medium, and high support), leggings (full length, 7/8, capri), shorts (running, cycling, compression), tops (tanks, crop tops, long sleeves), and coordinated matching sets. Each garment type has specific construction requirements — sports bras need elastic channeling, leggings need a gusseted crotch, and compression pieces need precise tension grading.

Yes. Recycled polyester (rPET) made from post-consumer plastic bottles performs identically to virgin polyester and is sublimation-compatible. ECONYL is a recycled nylon made from ocean waste and fabric scraps. Both options carry sustainability certifications (GRS, OEKO-TEX) and can be labeled as recycled content. Cost premium is typically 10–15% over conventional fabrics.