Table of Contents
- Quick Answer
- Why Sports Bras Are Harder to Manufacture Than Leggings
- My Experience Manufacturing Custom Sports Bras
- What Defines a High-Quality Sports Bra
- Step-by-Step: Custom Sports Bra Manufacturing Process
- Top Custom Sports Bra Manufacturers (With Links)
- Comparison Table
- How to Choose the Right Factory for Your Brand
- FAQs
- Work With Fukigymwear
Quick Answer
Manufacturing custom sports bras is primarily about support engineering, not just fabric or style.
From my experience, brands struggle with sports bras because they underestimate:
- Support structure
- Elastic behavior
- Cup and strap interaction
This guide explains how factories actually manufacture sports bras — and what brands must control to avoid fit failures, returns, and negative reviews.
Why Sports Bras Are Harder to Manufacture Than Leggings
Compared to leggings, sports bras:
- Carry more weight and tension in smaller areas
- Require more precise elastic control
- Must fit across cup size, not just waist/hip
A leggings fit issue might cause discomfort.
A sports bra fit issue causes lack of support or pain — which leads to immediate returns.
My Experience Manufacturing Custom Sports Bras
I’ve worked with brands producing:
- Light-support yoga bras
- Medium-support training bras
- High-support running and HIIT bras
- Longline and cropped bra tops
The biggest mistake I see:
Brands design sports bras visually, not structurally.
A good-looking bra that lacks proper internal support will always fail in real workouts.
What Defines a High-Quality Sports Bra
A high-quality sports bra must balance support, comfort, and durability.
| Element | What Matters | Why It’s Critical |
|---|---|---|
| Fabric | Stretch recovery | Prevents bounce |
| Elastic | Strength + rebound | Maintains support |
| Lining | Stability | Shapes and controls |
| Seams | Placement & strength | Prevents irritation |
| Straps | Width & elasticity | Distributes load |
Support comes from structure, not compression alone.
Step-by-Step: Custom Sports Bra Manufacturing Process
1. Support Level & Intended Use
Factories first define:
- Light support (yoga, pilates)
- Medium support (training, cycling)
- High support (running, HIIT)
Support level affects:
- Fabric GSM
- Elastic strength
- Strap width
- Internal structure
2. Fabric, Lining & Elastic Selection
Common materials:
- Nylon + Spandex (outer shell)
- Power mesh (internal support)
- Brushed lining (comfort)
- Reinforced elastic (underbust)
Elastic quality is often the deciding factor between good and bad sports bras.
3. Pattern Engineering & Size Grading
Sports bras require:
- Cup-aware pattern shaping
- Correct underbust tension
- Strap angle optimization
Poor grading leads to:
- Digging straps
- Loose underbust
- Insufficient support in larger sizes
4. Sampling, Fit Testing & Revisions
Sampling stages include:
- Prototype
- Fit sample
- Support test sample
- Size set samples
Fit testing should include:
- Jumping
- Running
- Stretch and recovery checks
5. Production, QC & Consistency
QC focus points:
- Elastic stretch and rebound
- Strap strength testing
- Seam stress testing
- Size measurement tolerance
Sports bras require tighter QC than leggings.
Top Custom Sports Bra Manufacturers (With Links)
1. Fukigymwear – Performance Sports Bra OEM
Specializes in custom sports bras with controlled support engineering and fit development.
Best for: Performance and private label activewear brands.
2. Affix Apparel – Custom Activewear Manufacturer
Offers low-MOQ custom sports bra manufacturing.
Best for: Startups testing multiple designs.
3. Argus Apparel – USA-Based Manufacturer
Provides design, sampling, and domestic production support.
Best for: Brands prioritizing USA-made sports bras.
4. Hucai Sportswear – OEM Activewear Factory
One-stop OEM solution for sports bras and gym wear.
Best for: Brands scaling bulk production.
5. Alanic – Global Sportswear Manufacturer
👉 Alanic
Large-scale production with global capacity.
Best for: Established brands expanding internationally.
Comparison Table
| Manufacturer | MOQ | Strength | Best For |
|---|---|---|---|
| Fukigymwear | Low–Mid | Support engineering | Performance brands |
| Affix Apparel | Low | Custom flexibility | Startups |
| Argus Apparel | Mid | USA OEM | Domestic positioning |
| Hucai Sportswear | Mid–High | Cost efficiency | Bulk orders |
| Alanic | High | Scale & capacity | Global brands |
How to Choose the Right Factory for Your Brand
- Yoga / studio brands: prioritize comfort and fabric feel
- Training brands: prioritize elastic and support testing
- Premium brands: prioritize QC and consistency
- Scaling brands: prioritize capacity and repeatability
Choosing the wrong factory shows immediately in sports bras.
FAQs
Q: What is the MOQ for custom sports bras?
A: Typically 100–300 pcs per style depending on structure and materials.
Q: Are sports bras harder to manufacture than leggings?
A: Yes — they require more structural engineering and tighter QC.
Q: Can support level be customized?
A: Absolutely. Support level is defined at the pattern and elastic stage.
Work With Fukigymwear
If you’re developing custom sports bras and need a factory that understands support, fit, and consistency,
👉 Fukigymwear offers end-to-end manufacturing support — from development to bulk production.
We help brands build sports bras customers trust during real workouts.
