Private Label Activewear: How to Launch a Gym Wear Brand from 100 Pieces
Activewear remains one of the highest-margin apparel categories for independent brands and one of the easiest to launch badly. Sheer leggings and twisted seams kill a new brand faster than any marketing mistake. Here is the manufacturing side of launching right, at small volume.
Step 1 Pick the fabric before the design
For leggings and fitted sets, the decision is nylon-spandex vs poly-spandex:
| Fabric | Feel | Best for | Cost |
|---|---|---|---|
| Nylon-spandex (76/24) | Buttery, matte | Premium yoga lines | Higher |
| Poly-spandex (82/18) | Smooth, holds prints | Training & fashion-led sets | Mid |
| Ribbed / waffle knits | Textured, lounge crossover | Sets that sell as streetwear too | Mid |
Whatever you choose, demand an opacity check at 240gsm or above for bottoms "squat-proof" is a measurable property, not a slogan.
Step 2 Build a tight first collection
The proven small-budget structure: one hero set (bra + legging or crop + flare), one cover layer (oversized tee or hoodie), one accessory colorway story. Three styles × two colors at 100pcs each = 600 pieces a complete brand launch, not a sample drawer.
Step 3 Branding that survives the gym
- Silicone heat transfer the modern standard for leggings waistbands; survives 50+ washes.
- Flat embroidery best on fleece, hoodies and waffle sets; avoid on thin spandex.
- Reflective print cheap upgrade that photographs well for running lines.
- Woven labels + hangtags included at 100pcs MOQ with most small-batch factories, ours included.
Step 4 Budget and timeline
A realistic plan from first email to sellable stock: quotes and fabric swatches (week 1), paid samples (weeks 2), revision and approval (week 4), bulk production (weeks 5), air shipping (week 10). Cash-wise, expect the bulk order to be 700% of total launch manufacturing cost, samples and shipping the rest.
Step 5 Test before you commit
The cheapest insurance: order existing stock styles from your shortlisted factory first. Two pieces of a stock yoga set tells you more about a supplier's stitching, fabric and grading than fifty emails. We built our activewear line around exactly this test-then-customize path request the line sheet to start.