For gym brands, fitness studios & private-label retailers

Custom Gym Clothing Manufacturers — Support High-Intensity Workouts for 2+ Hours

Four-way stretch fabric manages sweat through long sessions. Full custom cut, logo printing & colour matching available. Supply durable gym wear for fitness studios, private labels and wholesalers, helping you reduce return rates and boost repeat customer loyalty.

180%

Elasticity

260%

Faster drying

Long-lasting

Shape retention

Send a gym brief
OEKO-TEX 100BSCIGRS

Order facts

The commercial terms behind a gym run, before you send a brief.

Smallest run

100 pcs / colour

Sample window

7–10 working days

Bulk window

7–15 working days

Inspection

AQL 2.5

Freight is quoted DDP, DAP or DPU depending on the destination, and it sits on the quote rather than inside the piece price.

Before you commit

Four Places a Gym Order Stalls before It Reaches a Machine

None of these is about the design. They are the choices made after the range is signed off and before any cloth is cut.

First orders that have to be big before anything is proved

  • A minimum that only works at scale turns a new line into a bet on the whole season.
  • The colour that actually sells is rarely the one anyone predicted, and a big first run cannot chase it.

Our fix

Runs open small enough to prove a colourway on its own.

Samples that photograph well but train badly

  • Fit gets judged standing in a studio, then fails the first squat or the first overhead press.
  • Coverage and support problems only surface in movement, so a sample has to be moved in.

Our fix

The sample is worn and trained in before it is approved.

Reorders that come back a different shade

  • Shade drift between two runs of the same black is why a restock reads as a different product.
  • Split one colourway across two batches and it drifts, which shows only when the two sit together.

Our fix

One dye lot per colourway, with the sample kept as the control.

Suppliers who go quiet between the order and the delivery

  • Silence once the order is placed is where a launch date quietly slips.
  • Dates that live in an email thread are not dates a buyer can plan a campaign around.

Our fix

Dates are set on the quote, so progress can be checked against them.

The range

Nine Gym Pieces, Each One Cut to Your Own Block

What the grid describes is what each piece is for. The measurements underneath it come off the chart you supply, not off a stock block.

Stepped shot of high-waist leggings worn with a matching crop top, shot against a plain studio wall01

High-Waist Leggings

The piece most gym lines are built on — fitted through the hip and true through the waistband.

Fit
Close through the hip, high at the waist
Rise
Above the hip bone, held with a wide band
Seam
Flatlock through the leg, gusseted at the crotch
Seen from behind mid-stride in pale blue seamless leggings, the knitted zones reading as texture rather than a seam02

Seamless Leggings

Cut as one continuous tube where the machine allows it, so the side join comes out of the construction.

Fit
Second-skin, with no seam to rub
Rise
Knitted into the waistband itself
Seam
Woven out where the fabric allows, bonded elsewhere
Laid flat, grey lined shorts with the inner liner visible inside the right leg opening03

Lined Gym Shorts

A liner is built in, so the short can be worn without anything underneath.

Fit
Relaxed, cut to mid-thigh
Rise
Mid-rise, with an inner drawcord
Seam
Bound at the hem, flatlocked where it rubs
Modelled in a brown scoop-neck crop top with matching leggings, shown front on against white04

Sports Bras

Support is set by the brief, from a light studio fit to a hold built for impact work.

Fit
Band-held, with the support set by you
Rise
Set to your own measurement
Seam
No underarm seam at all — every edge is bound
Posed in a white ribbed tank tucked into denim jeans, one hand in the pocket05

Ribbed Tanks

Rib runs down the piece, holding shape and sitting well under a looser layer.

Fit
Straight, sitting close without clinging
Rise
Cropped to sit at the hip
Seam
Ribbed band at the neck, flatlock below it
Suspended flat, a black lifting suit with a short leg and bound armholes, on a white ground06

Lifting Singlets

Overhead work sets the cut here, with a shoulder strap placed to clear a bar.

Fit
Fitted at the chest, loose at the armhole
Rise
Short at the torso, built for a bar path
Seam
Reinforced at the shoulder, bound at the armhole
Zipped up in a bright orange hoodie with white drawcords, a kangaroo pocket and ribbed cuffs07

Zip-Through Gym Hoodies

Warm-ups unzip, so this layer is built to come off between sets and go back on.

Fit
Roomy enough for a layer underneath
Rise
Standard, ending at the hip
Seam
Zip set on a band, flatlock through the body
Walking in light grey tapered joggers with an elasticated waist and cuffed ankles08

Gym Joggers

Tapered rather than baggy, this is the piece a member arrives and leaves in.

Fit
Tapered to the ankle
Rise
Elasticated at mid-rise
Seam
Drawcord threaded internally, flatlock legs
Matched cream set of a fitted cami and wide-leg cropped trousers, worn on one model09

Matching Two-Piece Sets

One colourway, two pieces, cut from the same cloth so the set reads as a set.

Fit
Matched across both pieces
Rise
Cut to match across both pieces
Seam
Both pieces finished the same way, so the set is consistent

Price a gym range

Knit library

Six Knits, and the Job Each One Does in a Gym Piece

The knit decides how the piece moves, how it recovers and how it takes decoration. Choose it against the way the piece is worn, then lock the weight and the hand on the sample.

Textured macro of a green four-way stretch knit, swirled into a rosette so the grain reads across the frame

Four-way stretch knit

The base for anything that has to move. Stretch runs in both directions, so the piece recovers its shape instead of growing at the knee.

Usually specified forLeggings · Shorts · Bras

Raised in a grid across a blue engineered knit, the waffle cells and their creases reading as texture

Engineered seamless knit

Zones are built into the knit rather than cut and joined, which puts the support where the body needs it and takes a seam out of the picture.

Usually specified forBras · Tanks · Seamless sets

Brushed fleece in heathered grey, swirled into a spiral so the nap reads evenly across the frame

Brushed fleece and loopback

For the layers a session starts and ends in — warm to the hand and stable enough to hold a hood.

Usually specified forHoodies · Joggers · Sets

Tightly knitted compression fabric in black, curled to show the dense gauge as a fine even rib

Compression knit

A tighter gauge that holds the muscle rather than only covering it, read from the brief instead of a stock card.

Usually specified forSupport wear · Singlets · Shorts

Lower-impact options

Folded through a bright lime recycled polyester knit, the fine diagonal grain running across the frame

Recycled polyester (rPET)

Reclaimed plastic goes in at the fibre stage rather than as a coating, for a range whose story is the material itself.

Usually specified forShorts · Leggings · Kit

Spiralled in dusty rose, an organic cotton blend knit with a fine rib running across the frame

Organic cotton blend

Grown to organic rules and traceable to the field, blended to soften a knit that would otherwise be all synthetic.

Usually specified forTanks · Loungewear · Sets

Weight, blend and hand are quoted against your own tech pack · nothing here is a stock fabric

Grading & fit

A Size Run Built on Your Chart, Not a Stock Block

Grading decides whether one size suits a member who trains twice a week and one who competes. The three ranges below are the ones this mill grades for.

Grading diagram marking the shoulder, chest and waist on a tee, over four colour swatches

Men's

Blocks start from the shoulders, so a size that fits the chest still moves across the back.

  • Shoulder, chest and waist are graded on separate steps rather than scaled together.
  • Sleeve and leg length are held per style, so one piece can be short and another long.

Graded onYour own chart, or a garment that already fits

Measurement diagram marking the bust, waist, hip, rise and waistband height on a body form

Women's

The block is drafted for the hip and the bust together, which is where an adapted men’s pattern always fails.

  • Bust and hip are graded independently, so the waist does not follow either one.
  • Rise and waistband height are set per style rather than carried over from the last one.

Graded onYour own chart, plus the rise you want

Line drawing of a long-sleeve tee with a ruled callout down its right side marking the body length

Plus

Sizes extend upward on the same block rather than being scaled off a smaller one, so the proportions hold.

  • Graded on its own steps instead of enlarged from a smaller size.
  • Length and placement are proved in movement, not only measured on a form.

Graded onYour own chart, with the fit checked in movement

Every size is proved on a worn sample before the run · the same block is used for the whole colourway

Decoration

Which Decoration Goes on Which Gym Piece

The method follows the panel, not the other way round — a mark that flexes at a different rate from the cloth under it is the one that fails first.

Mesh screen lifted off a blue tee on the press bed, the white design still sitting on the stencil

Sublimation

  • All-over pattern is dyed into the fibre, so the print has no surface layer to crack.
  • Poly/spandex takes it best, which is what leggings and tanks are cut from.

Usually chosen forLeggings · Shorts · Tops

Screen flooding with red ink as a squeegee is pulled across the mesh of a carousel press

Screen print

  • Spot colour goes on a finished piece, with the ink coverage set to the knit.
  • A flat, stable panel suits it; a stretched seam does not.

Usually chosen forTanks · Hoodies · Tees

Silicone wordmark with the transfer film peeled back, the raised lettering left on white fabric

Heat transfer and silicone

  • Heat and pressure lay a fine mark that flexes with the fabric.
  • Where a wordmark sits on stretch, this is what makes it disappear into the wear.

Usually chosen forBras · Leggings · Tops

Flat placeholder lettering reading Your DESIGN Here on the chest of a green tee worn by a model

Embroidery

  • Raised stitching the buyer can specify, on a piece that does not move much.
  • Hoodie chests and jogger thighs carry it; a stretched panel will not.

Usually chosen forHoodies · Joggers · Sets

Artwork is proofed on the garment’s own cloth before the run · the method is locked on the sample

Screen printing, in detailSublimation, in detail

Lock the spec on a body

Block, Knit and Decoration Settled on One Worn Sample

Sampling is priced separately, and the bulk schedule opens the day that sample is signed — so nothing sits unscheduled between the two.

Quote the sample set

Where we sit

Three Routes to a Gym Range, Side by Side

The differences that matter are where the order size sits and how much of the garment you actually control.

 JaceApparelOur routePrint-on-demandHigh-MOQ factory
Order minimum100 pcs per colourSingle piecesA long first run
The pieceYour block, your rise, your seam planA ready-made blank, decoratedTheir house block, modified for you
FabricAgreed with you, then written into the tech packThe one knit that item comes inWhatever the mill buys in bulk
DecorationAll-over dye, spot colour, transfer or stitchDigital transfer onto a finished itemOnly what their machines already run
Fit and stretchMoved in before the sample is signed offUntestedDrafted for a figure standing still
SampleA wearable piece, made before the bulkScreen proof onlyCharged development, quoted up front
Lead timeWindow dated on the quoteWhenever you upload, in daysWhen their calendar allows
Best forBrand lines starting from a small runOne-off test piecesHigh-volume programmes

Client files

Gym Programmes, and What the Buyers Reported

A named buyer, what was going wrong, what the mill changed, and what the client said afterwards.

GX-01Natalie Reed, in a black blazer over a lilac top, smiling inside a vaulted stone arcadeNatalie ReedFounderPeak Form FitnessBoutique studio, 180+ monthly members, retailing branded tees and leggingsUnited Kingdom120 pcs · one colourway

Squat-proof leggings for a studio’s member retail

Pain point

  • Previous supplier set the minimum at 500 pieces a colour, and the studio needed 120 — cash tied up in stock it might not sell.
  • The fabric carried no anti-odour treatment, and members complained about a lingering smell after HIIT sessions.
  • Leggings went see-through in a squat, and the reviews that followed landed on the studio rather than the garment.
  • Sampling ran 18–22 days, which pushed the drop past the member promotion it was ordered for.

Our solution

  • A single colourway at 120 pieces, sizes mixed inside it, so the studio cleared the order minimum without buying a colour it did not need.
  • Four-way stretch, moisture-wicking knit with an anti-odour finish, tested to cut bacterial build-up by 92%.
  • Custom grading for European body shapes, plus a double-lined construction at the seat, so the squat test stopped being the problem.
  • Sampling inside our 7–10 working day prototype window, with a silicone logo, woven neck labels and custom hang tags on the finished piece.

Client-reported results

  • The return rate fell from 11% to under 3% once the fit and the finish were in place.
  • Gym apparel retail revenue rose 38% within three months of the drop.
  • A reorder was placed four months after the first batch.

“We only had a small budget for gym merchandise and couldn’t risk locking cash into large inventory. The squat-proof leggings and anti-odour fabric solved our biggest member complaints. Communication was clear, samples arrived quickly and our branded gym wear became one of our most popular member perks. I will keep reordering.”

Natalie Reed, Founder, Peak Form Fitness
GX-02Mark Torres, in sunglasses and a blue jacket, sitting in the driver’s seat of a carMark TorresFounderTorus ActiveA four-person DTC brand selling seamless gym sets onlineAustralia

Seam and colour fixes for a four-person DTC brand

Pain point

  • Flatlock seams from the previous factory tore after repeat washes, and the raw edges chafed mid-session.
  • Colour drifted between bulk batches, and the Pantone match failed more than once.
  • Bulk production ran 52 days and the collection landed past its influencer launch window.
  • No fibre or performance test reports came with the goods, so the listings had nothing behind them.

Our solution

  • Reinforced flatlock seams on a knit that keeps its shape past 100 washes.
  • Pantone approval was taken on a pre-production strike-off, and every batch was cut against that signed colour.
  • Fast-tracked inside our 7–15 working day bulk window, on a schedule built back from the launch date.
  • Full test reports on stretch, pilling and moisture wicking, raised on the order and handed over with the cartons.

Client-reported results

  • The defect rate came down from 9% to 2.1% across the first two runs.
  • Launch stayed on schedule, and the first batch sold out in 27 days.
  • Reorder volume rose 120% on the second production run.

“As a tiny startup, we cannot afford quality inconsistencies or missed deadlines. Their technical team fixed our seam and colour issues. The performance fabric data we received helped us build trust on our Shopify page and reduce customer questions. Reliable partner for our small brand growth.”

Mark Torres, Founder, Torus Active

In the gym

Gym Kit on the People Who Ordered It

Mirror selfie in a black graphic tee and shorts, headphones round the neck, orange-framed machines behind
Lifting a loaded barbell off the floor in a black tank and panelled shorts, head down beside an orange barrel
Making a peace sign in a grey ribbed tank and shorts, a second phone held up in the other hand
Flexing side-on in a black lifting singlet, the phone raised in the other hand against a mirrored wall
Resting on a bench between sets in a black sleeveless tee, headphones still on
Standing in a grey sleeveless tee and shorts for a mirror selfie under a purple ceiling light

Questions

Frequently Asked Questions About Custom Gym Clothing Manufacturers

01What is the smallest gym clothing order you will take?

A gym range opens at 100 pieces in a single colour, and the same count applies to each colour you add rather than to the order as a whole. Sizes do not break that count down — three sizes inside one colour are still a hundred pieces in that colour, not three hundred.

Ask about a first gym run
02Will you grade from the chart we supply?

Sizes are cut against your own measurements rather than a stock chart, so a longer inseam or a wider hip changes how a panel is shaped — not just the size printed on the label.

See how a size run is built
03Do we approve a sample before bulk?

One pre-production sample is made in your own fabric and worn before bulk; the sewn window opens at 7–10 working days once the tech pack locks, and 3–5 fit revisions sit inside it. Sampling is US$80–150 per style, credited against a bulk run of 500 pieces or more.

Price the sample first
04How long does the line run after the sample is approved?

The line runs for 7–15 working days once the approved sample is in its hands. A colourway added later re-enters the schedule at cutting, on a block that is already locked, so nothing downstream moves.

Ask when the line would run
05What happens at the final check?

Each carton is checked at AQL 2.5 against the sample you signed, one box at a time. A seam that has slipped or a print that has faded is far cheaper to find on the floor than after the goods have crossed a border.

See how the floor checks it
06Which documents follow a gym order?

Every order leaves with its paperwork: the fibre list, the wash instructions and the test reports raised on that order. Anything else your importer needs for their file can be asked for while the quote is still open.

Ask what travels with the order
07How does a gym order reach us?

By air in 5–7 days or by sea in 30–45, whichever suits the date you are working to. Air costs more and lands sooner; sea is the cheaper route when the calendar has room.

Ask which route is quicker
08Do the pieces go out under our name?

They do. The woven label, the care label, the heat transfer and the polybag are all built from the artworks you supply, and the label carries a minimum of its own, counted apart from the garment.

Ask how labelling is counted

Next step

Your Block, Your Fabric and Your Count Are Enough to Quote

The quote breaks the knit, the making and the decoration into separate lines, so a gym range can be priced before anything is cut.

Bring your tech pack

Prefer email?info@jaceapparel.com

Request a quote