Most new activewear brands do not fail on design. They stall on manufacturing: unclear minimums, samples that do not fit, or a launch date that slips by months. This checklist walks through every step in order.
1. Define your product and price point
Start with one hero product, usually leggings or a matching set. Decide your retail price first, then work backwards: most brands aim for a manufacturing cost well under a third of retail to leave room for shipping, duties, marketing and margin.
2. Choose your fabrics
Fabric decides feel, opacity and price more than anything else. Nylon-spandex blends feel soft and premium; polyester-spandex is more affordable and holds sublimated prints well. Order swatches before you commit.
3. Create a tech pack
A tech pack is the blueprint a factory follows: technical sketches, measurements, fabrics, trims, colors and branding placement. A clear one prevents most sampling problems.
- Front, back and detail sketches
- Measurement chart for every size
- Fabric, trims and color references
- Logo artwork, size and placement
4. Find a manufacturer
Shortlist factories that publish their minimums, specialize in activewear and can show you production photos. Ask for sample pricing, lead times and payment terms in writing.
5. Sample, then order bulk
Test samples hard: squat, stretch, wash. Expect one or two rounds of revisions. Only pay the bulk deposit once the final sample is exactly what you want to sell.