How to Start a Custom Athleisure Line for Women

Table of Contents


Quick Answer

Starting a custom athleisure line for women means creating a product collection (leggings, tops, jackets, sets) that reflects your brand identity — and selling it with your label.

From my experience helping brands launch their first collection, success comes down to:

  • Picking the right fabrics
  • Partnering with the right manufacturer
  • Testing fit before bulk production

This guide walks you step by step — from concept to production — and highlights real manufacturers you can contact today.


Why Athleisure Is a Smart Business Move

Athleisure blends comfort + performance + fashion — making it one of the fastest-growing apparel categories.

Women’s athleisure sells because:

  • Consumers want clothing that works from gym → errands → social
  • High perceived value boosts price tolerance
  • Repeat purchases happen when fit and comfort are great

In short: athleisure is both functional and fashionable — perfect for new brands.


My Experience Starting Athleisure Lines

I’ve helped multiple brands start women’s activewear collections, including:

  • Leggings and crop tops
  • Performance hoodies and jackets
  • Athleisure sets and jumpsuits

Here’s what I learned the hard way:

  • The biggest mistakes happen when fabric stretch fails in real wear
  • Poor pattern grading results in inconsistent sizing
  • A bad zipper or seam can tank an otherwise great product

Good planning and the right manufacturer make all the difference.


What Athleisure Really Means (Definitions)

In apparel terms:

Athleisure =
Comfort-oriented apparel with performance features + everyday wearability.

Athleisure Categories Often Include:

  • Leggings & tights
  • Sports bras & crop tops
  • Sweatpants & joggers
  • Hoodies & jackets
  • Sets & matching outfits

This differs from strictly performance athletic wear, which is optimized exclusively for sport.


Step-by-Step Guide to Starting Your Custom Athleisure Line

1. Define Your Brand Identity

Start with:

  • Target customer (e.g., active moms, yoga lovers, streetwear)
  • Price positioning (budget, mid, premium)
  • Visual style (minimal, bold, retro)

Your identity determines fabric choice, branding, and pricing.


2. Choose Key Products

Start with a small capsule collection:

  • Leggings
  • Tops
  • Outerwear
  • Sets

Avoid launching with 50 styles — focus on 3–6 hero products first.


3. Source Materials & Fabrics

Good materials = bottom-line product experience.

Common fabrics:

  • Nylon + Spandex — great stretch
  • Polyester blends — moisture-wicking
  • French terry — lifestyle comfort

Always check:

  • Shrinkage
  • Pilling
  • Colorfastness

4. Choose a Manufacturer

Your manufacturer affects:

  • Fit consistency
  • Fabric supply chain
  • MOQ flexibility
  • Branding options (labels, trims, packaging)

We’ll list solid options below.


5. Sampling and Fit Testing

Never skip samples.

You want to test:

  • Stretch & recovery after 10+ wears
  • Fit across all sizes
  • Seam strength

Ask for fittings on real bodies — not just flat measurements.


6. Production & Quality Control

Before bulk runs:

  • Establish clear QC checkpoints
  • Confirm size grading is consistent
  • Request pre-shipment photos

Good quality control prevents returns and bad reviews.


Here are five reputable manufacturers you can contact:

1. Fukigymwear – Custom Activewear OEM

👉 Fukigymwear

Full-service activewear production from sampling to delivery.

Best For: Startups and growth brands


2. Apliiq – Custom Apparel & Branding

👉 Apliiq

Custom branding, embroidery, and low MOQ options.

Best For: DTC brands and fashion-forward lines


3. AS Colour – Premium Blank & Custom Supplier

👉 AS Colour

High-quality blanks and fabric customization.

Best For: Modern lifestyle athleisure


4. Next Level Apparel – Comfort-First Supplier

👉 Next Level Apparel

Soft fabrics and contemporary fits.

Best For: Casual athleisure pieces


5. Stanley/Stella – Sustainable Apparel Manufacturer

👉 Stanley/Stella

Known for eco-friendly materials and ethical production.

Best for: Sustainability-driven brands


Comparison Table

Manufacturer MOQ Customization Best For Strength
Fukigymwear Low ⭐⭐⭐⭐⭐ Full OEM Custom development
Apliiq Low ⭐⭐⭐⭐ Branding Fast launch
AS Colour Medium ⭐⭐⭐⭐ Premium blanks Fabric quality
Next Level Apparel Medium ⭐⭐⭐ Comfort basics Availability
Stanley/Stella Medium ⭐⭐⭐⭐ Sustainable brands Ethical supply

How to Choose the Right Manufacturer for Your Line

✔ Want full OEM & custom development → Fukigymwear
✔ Need quick branding → Apliiq
✔ Premium fabric focus → AS Colour
✔ Soft everyday styles → Next Level Apparel
✔ Sustainability-first → Stanley/Stella


FAQs

Q: What is the typical MOQ for athleisure?
A: Usually 50–300 units depending on fabric and complexity.

Q: Can I customize labels and packaging?
A: Yes, most manufacturers offer full private label options.

Q: How long does production take?
A: Sampling: 10–20 days. Bulk production: 30–45 days.


Work With Fukigymwear

If you’re ready to launch your custom athleisure brand,
👉 Fukigymwear provides full-service manufacturing — from concept to delivery.

We help brands launch faster, reduce risk, and scale with confidence.

owen@bless-dg.com

Recent Posts

Jumpsuit Pattern Development Guide

Table of Conten…

1 天 ago

Private Label Workout Jumpsuits

Table of Conten…

1 天 ago

Fitness Jumpsuit Factory Workflow

Table of Conten…

1 天 ago

Custom Gym Jumpsuit OEM

Table of Conten…

1 天 ago

Jumpsuit Fabric and Stretch Setup

Table of Conten…

1 天 ago

Activewear Jumpsuit Manufacturing

Table of Conten…

1 天 ago