Step 1: Pick one sport and one hero product
One sport, one hero product.
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Runners, yoga teachers and gym lifters want different things. Choose one, then choose one product such as high-waisted leggings or a running short. A single product that fits well will sell your next one. Check what competitors sell and read their bad reviews. In activewear these often mention see-through fabric, rolling waistbands and poor fit, and each one is a chance for you.
Step 2: Test demand before you pay for stock
Ask the people who actually train in it.
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Show your idea to the people who train in it. Ask studio owners, coaches and club members what they wear and what annoys them. A waiting list or pre-orders from this group is worth more than any survey.
Step 3: Choose the fabric first
In activewear, the fabric is the product.
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Fabric decides how the garment fits, feels and costs, so choose it before you draw the details. Most activewear blends nylon or polyester with elastane for stretch and recovery. Ask your supplier for swatches and stretch them yourself. Check that the fabric stays opaque when stretched, recovers its shape, and feels right against the skin. Use the fabric finder at the top of this page as a starting point. Fabric mills can set their own minimums, so ask if a fabric is in stock or made to order.
Step 4: Cut-and-sew or seamless?
Start with cut-and-sew unless you need seamless.
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This choice decides which factories you can work with.
| Method | What it means | Good for | Watch out for |
|---|---|---|---|
| Cut-and-sew | Fabric panels are cut and sewn together, often with flat seams | Most designs, pockets, colour blocking | More seams to test for comfort |
| Seamless | The garment is knitted in one tube on circular machines | Close-fitting pieces, shapewear, sports bras | Needs specialist factories, and minimums are often higher |
If you are not sure, start with cut-and-sew. It gives you more freedom and a wider choice of manufacturers.
Cut-and-sew
- Design freedom
- Seam comfort
- Good for
- Most designs, pockets, colour blocking
- Watch out for
- More seams to test for comfort
Seamless
- Design freedom
- Seam comfort
- Good for
- Close-fitting pieces, shapewear, sports bras
- Watch out for
- Needs specialist factories, and minimums are often higher
Step 5: Protect your name and set up the business
Protect the name, then set up the business.
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Check that your name is free, then register it in Nice class 25, which covers clothing. Set up your company and VAT before your first invoice. Our guide on how to start a clothing brand covers these steps and the fees.
Step 6: Write a tech pack for stretch
Stretch fabric needs more detail than a T-shirt.
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Activewear needs more detail than a T-shirt. Add the fabric composition, seam type, waistband build, gussets and any compression you expect. Measurements change under stretch, so state how they are taken. Start with our free tech pack template. Then send the same document to every factory, so that quotes can be compared.
Step 7: Find sportswear manufacturers
Pick factories that have made this exact product.
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Contact three to five suppliers and ask if they have made this exact product. A factory that sews T-shirts may not have the machines for flat seams or elastic fabrics. Ask to see similar garments, and ask for the MOQ per style and per colour.
Manufacturers for a small first run
Manufacturers for a larger batch
Always confirm the MOQ with the supplier, because it depends on fabric, construction and colours. Compare more options on our page for sportswear manufacturers in Europe, and read about custom sportswear manufacturing.
6 suppliers
CREATE FASHION BRANDPortugal
From 50 MOQ
Sportswear
NB TextilePortugal
From 50 MOQ
Sportswear
Raka TextilGermany, Turkey, Portugal
From 50 MOQ
Sportswear
JasebitextileTurkey
From 100 MOQ
Sportswear
JeetexTurkey
From 100 MOQ
Sportswear
From 100 MOQ
Sportswear
WAT.Portugal
From 200 MOQ
Sportswear
SahinbeytekstilTurkey
From 150 MOQ
Sportswear
- Vera Nadar Tekstil
Turkey
From 150 MOQ
Sportswear
Dany fashion ltdBulgaria
From 300 MOQ
Sportswear
PTMGPortugal
From 300 MOQ
Sportswear
Seam FactoriesPortugal
From 300 MOQ
Sportswear
SeamlessnfTurkey
From 500 MOQ
Sportswear
Ready to talk to suppliers?
Step 8: Wear-test your samples
Squat, stretch, sweat and wash before you approve.
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Do not approve a sample by looking at it. Wear it for what it is made for:
- Squat in front of a bright light to check opacity
- Stretch it, then check that it recovers
- Sweat in it and check for rubbing at the seams
- Wash it several times, then compare shape and colour
Ask people with different body shapes to test it too. Write down each correction and send it to the factory before you approve the next sample.
Wear test
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Step 9: Get labels and claims right
Keep proof for every performance claim.
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Clothing sold in the EU needs a fibre composition label, including elastane, in the language of the country of sale. See our guide to clothing labels in Europe. Activewear marketing is full of claims, so keep proof for each one:
- Moisture-wicking or quick-dry: ask for test results for your fabric.
- Antibacterial or odour control: if the fabric contains a biocide, EU rules on treated articles can apply, including labelling.
- Recycled: ask for a certificate and check that it covers your fabric. EU rules on general green claims became stricter in September 2026.
France also restricts PFAS in clothing since January 2026, so ask your supplier about any water-repellent finish. In France you must also register with Refashion from your first unit sold.
- Moisture-wicking
Have proofAsk for test results for your fabric.
- Antibacterial
Have proofIf the fabric contains a biocide, EU rules on treated articles can apply, including labelling.
- Recycled
Have proofAsk for a certificate and check that it covers your fabric. EU rules on general green claims became stricter in September 2026.
Step 10: Launch with people who train
Coaches and studios sell activewear for you.
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Activewear sells through trust. Give samples to coaches, studios and clubs in your niche, and ask for honest feedback before you ask for promotion. Photograph your product in real use, then launch to your waiting list. Studios can also become your first wholesale customers.
Frequently asked questions
How much does it cost to start an activewear brand?
It depends on your fabric, construction and MOQ. Multiply the MOQ by your styles and colours, then by your unit quote. Then add samples, labels, shipping, trademark and marketing. Seamless production can mean higher minimums than cut-and-sew.
What is the best fabric for leggings?
Most leggings use nylon or polyester blended with elastane. Nylon often feels softer, while polyester often costs less and dries fast. Test swatches for stretch, recovery and opacity before you decide.
What is a good MOQ for a new activewear brand?
One you can sell without discounting. The suppliers listed above show their current minimums, and small runs are possible with cut-and-sew. Ask if the MOQ applies per style or per colour.
Should I choose seamless or cut-and-sew?
Cut-and-sew suits most new brands because it gives more design freedom and more factory choice. Seamless suits close-fitting pieces if you can meet the factory's minimum.
Can I print my logo on leggings?
Yes, but choose a method that stretches with the fabric. Ask your factory to test the logo on your exact fabric, then stretch and wash the sample.