When manufacturing custom gym bras, long-term performance depends on three non-negotiables:
From my experience, most gym bra failures are not design problems — they are material and elastic decisions made too early and never validated properly.
Gym bras are worn under constant tension.
If materials or elastic are wrong, problems appear quickly:
Factories that scale successfully treat materials and elastic as engineering components, not styling choices.
I’ve worked with brands producing:
The most common mistake I see:
Brands approve samples based on feel, not performance data.
Gym bras must be evaluated after stretch, wash, and repeated wear, not just during fitting.
The outer fabric defines comfort, stretch, and durability.
| Material | Typical Use | Notes |
|---|---|---|
| Nylon + Spandex | Most gym bras | Best stretch recovery |
| Polyester + Spandex | Budget options | Less rebound |
| Power mesh | Internal lining | Adds control |
| Brushed lining | Comfort layer | Skin feel improvement |
Key rule:
Fabric recovery matters more than fabric weight.
Elastic quality determines how long a gym bra maintains support.
Critical elastic standards:
| Elastic Area | Common Failure | Factory Fix |
|---|---|---|
| Underbust | Rolling / loosening | Higher rebound elastic |
| Straps | Loss of tension | Reinforced strap elastic |
| Arm openings | Digging | Softer elastic with control |
Cheap elastic is the fastest way to destroy a gym bra.
Professional factories define fit standards clearly.
Minimum fit requirements:
Fit must be tested:
Reliable factories perform:
If a factory cannot show test methods, results are guesswork.
Specializes in gym bras with controlled material sourcing, elastic testing, and repeatable fit standards.
Best for: Performance and private label activewear brands.
Offers flexible development and low MOQ gym bras.
Best for: Brands testing materials and designs.
Domestic production with structured development support.
Best for: USA-made gym bras.
OEM factory supporting bulk gym bra production.
Best for: Cost-efficient programs.
👉 Alanic
Large-scale activewear manufacturing.
Best for: Established international brands.
| Manufacturer | Material Control | Elastic Testing | Best For |
|---|---|---|---|
| Fukigymwear | Strong | Strong | Performance brands |
| Affix Apparel | Medium | Medium | Startups |
| Argus Apparel | Medium | Medium | USA OEM |
| Hucai Sportswear | Medium | Basic | Bulk orders |
| Alanic | Standardized | Standardized | Global scale |
Clear standards protect both quality and margins.
Q: Why do gym bras feel loose after washing?
A: Low-quality elastic or insufficient recovery testing.
Q: Can elastic be customized?
A: Yes — width, strength, and rebound can all be specified.
Q: Should fit standards change by support level?
A: Yes. Higher support requires tighter tolerances.
If you’re developing custom gym bras and want reliable materials, elastic, and fit standards,
👉 Fukigymwear supports brands with structured development and stable production systems.
We help brands avoid the most common gym bra quality failures.