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Custom Activewear Manufacturer For New York Brands, Retailers & Gyms
Private Label Leggings, Sports Bras & Seamless Sets Built to Your Exact Specifications
We are a New York-oriented custom activewear manufacturer offering end-to-end OEM and ODM production services for fitness brands, fashion entrepreneurs, and sportswear labels at every stage of growth. From your first 50-piece sample order to a 5,000-unit bulk run, we engineer high-performance gymwear using premium nylon-spandex blends, technical construction methods, and full private label branding capabilities.
Every garment we manufacture is built around four non-negotiable pillars: fabric performance, structural precision, sculpted fit, and brand-ready finishing. Whether you need high-waist sculpt leggings with a V-back waistband and contour glute seams, medium-to-high-support sports bras with removable padding, or a fully coordinated seamless activewear set — our New York production team delivers.
We work with brands across New York City, the greater United States, Europe, and Latin America, providing the same level of technical precision and customization support to a first-time brand founder as we do to an established activewear label scaling into new markets.
Our Manufacturing Unit & Process
Our Shipping Partners
We Serve New York Activewear Like No Other
Responsive Communication in New York Time Zone
As we actively work with brands, retailers, and gyms across New York, we align our communication with your local time zone (GMT -4). Whether you need a quick call, pricing, or production consultation, our team responds promptly during your working hours—ensuring fast, clear, and seamless communication.
Shipping Cost to New York
With our manufacturing facility based in Pakistan and regular deliveries to New York, shipping costs are an important factor to consider. Our standard rate starts at $62 for the first kilogram, with an additional $16 per kilogram thereafter. For bulk orders, shipping rates are significantly reduced and negotiable.
Shipping Timeline to New York
Our standard delivery timeline to New York, USA is 12–14 working days for both samples and bulk orders. For urgent requirements, we can expedite production and shipping to meet tighter deadlines. We ensure reliable and consistent delivery timelines for all New York clients.
New York Brand Success Story
A New York-based fitness startup partnered with us to launch its first activewear collection. Starting with a small order, the brand quickly gained traction due to premium quality and design. Within months, they scaled production, expanded their product line, and built a strong presence in the competitive NYC fitness market.
Payments We Accept
About Our New York Activewear Manufacturing Service — Who We Are and Why It Matters
For over a decade, our team of garment engineers, pattern makers, and performance fabric specialists has been developing custom activewear collections for private label brands across New York and internationally. We are not a sourcing agent, a dropshipper, or a catalog reseller. We are a technical manufacturing partner — a studio where your garment specifications are engineered from the fiber level upward.
Here is what we offer activewear brands in New York:
- Technical sportswear pattern making and grading for performance fit
- Nylon-spandex fabric sourcing and GSM specification across international textile mills
- Garment construction methods including flatlock stitching, seamless knitting, bonded seam technology, and coverstitch finishing
- Compression garment engineering for both aesthetic sculpting and functional athletic support
- Private label branding techniques including silicone printing, heat transfer application, sublimation, embroidery, and woven label integration
- Quality assurance protocols covering stretch recovery, opacity testing, seam stress testing, and wash durability
We have manufactured collections for brands ranging from solo fitness influencers launching their debut 100-set collection in New York to sportswear companies producing 3,000+ units per style across multiple seasonal colorways.
Our manufacturing philosophy is grounded in one belief: a great activewear brand cannot be built on mediocre construction. The fit, the fabric, the seam placement, the waistband engineering — every detail affects how a garment performs on the body, how it photographs, and how customers respond to it. That is why we treat every client order — regardless of order size — with the same technical rigor we apply to our largest production runs.
Our Certifications
Custom Activewear Products We Manufacture for New York Private Label Brands
Our New York activewear manufacturing studio produces a core range of performance gymwear styles, each engineered to meet the exacting demands of modern fitness consumers. Every style we offer can be customized in fabric composition, GSM weight, compression level, colorway, sizing range, seam construction, and branding placement. Below is our complete product lineup with full technical specifications.
High-Waist Sculpt Leggings — Custom Manufactured in New York
High-waist leggings remain the single most requested product from brands we work with across New York and beyond. Our legging production program is built around one core principle: sculpting fit that performs under real movement conditions without sacrificing aesthetic appeal.
Construction Specifications:
Our standard high-waist sculpt legging features a deep-cut waistband that sits 3 to 4 inches above the natural waist, engineered to stay in place without rolling during high-intensity movements including squats, lunges, and plyometrics. The waistband construction uses a double-layer fabric panel bonded at the top edge to eliminate the curl-and-fold failure mode that affects single-layer waistband designs.
The back waistband can be manufactured in a V-shape cut, which creates a visual elongation of the torso and a lifting effect on the glute region — one of the most commercially requested design features among private label brands currently launching in New York and across the US.
Our no-front-seam construction eliminates the vertical center seam that bisects the front of standard leggings, producing a cleaner premium appearance and eliminating a common source of comfort complaints. The crotch panel is cut and sewn using a gusset construction method that allows full range of motion without tension pulling across the hips or inner thigh.
Contour seams beneath the glute region are available as a standard customization, engineered to follow the natural curve of the gluteus maximus and gluteus medius muscle groups, creating a lifting and rounding visual effect without the use of padding inserts.
Technical Specifications:
| Specification | Detail |
|---|---|
| Waistband height | 3–4 inches / 8–10 cm |
| Available lengths | 7/8 length (ankle), full length, capri (optional) |
| Seam construction | Flatlock stitch (4-thread), coverstitch finish |
| Waistband construction | Double-layer bonded, no-roll engineering |
| Crotch construction | Diamond gusset panel |
| Optional features | V-back cut, contour glute seams, mesh side panels, phone pocket |
| Compression level | Light (180–200 GSM), Medium (210–240 GSM), High (250–280 GSM) |
| Squat-proof rating | All fabrics above 200 GSM tested for opacity at 45-degree angle |
| Stitch density | 16–18 stitches per inch on primary seams |
Sports Bras — Medium to High Support Custom Manufacturing
Our sports bra manufacturing program covers the full spectrum of support levels, cup constructions, and strap configurations currently in demand among New York activewear brands. We engineer each bra to perform functionally during training while maintaining the aesthetic design language of your brand.
Medium Support Construction:
Medium support sports bras are engineered for activities with moderate impact — yoga, Pilates, reformer training, lightweight lifting, and cycling. Our medium support construction uses a single-layer stretch fabric body with a reinforced underband cut from a higher-density fabric panel (typically 240–260 GSM) to provide upward lift without the rigidity of underwire. Built-in cups are sewn into a separate interior pocket — allowing removal for washing and personal preference — and are cut from a compression foam insert that maintains shape retention through repeated compression and release cycles.
Medium-High and High Support Construction:
High support bra construction introduces a secondary interior layer across the bust zone, constructed from a tighter nylon-spandex blend (78% Nylon / 22% Spandex at 250–270 GSM) bonded to the outer shell fabric. This creates a compression encapsulation system that minimizes vertical bounce during high-impact activities including running, HIIT, and plyometric training. The underband is constructed with a non-elastic interior channel that distributes pressure across the full circumference of the rib cage, eliminating the pinch points common in elasticated-only underband designs.
Strap Configurations Available:
- Straight parallel straps (basic configuration)
- Adjustable hook-and-loop straps
- Thick fixed straps (3 cm+ width — most popular for aesthetic appeal and shoulder comfort)
- X-back cross strap design (signature back design used by multiple NY brands)
- Racerback panel
- Spaghetti straps for low-impact styles
Technical Specifications:
| Specification | Detail |
|---|---|
| Cup construction | Removable pad pocket (standard) / molded cup (optional) |
| Underband construction | Double-layer reinforced / non-rolling hem finish |
| Strap width options | 1.5 cm, 2 cm, 3 cm, custom |
| Back constructions | X-back, racerback, straight, open-back |
| Logo placement zones | Underband center, front chest center, strap webbing |
| Breathability | Optional mesh back panel, perforated zones |
| Support levels | Light / Medium / Medium-High / High |
Seamless Activewear Sets — Knit-to-Shape Manufacturing
Seamless activewear represents the highest level of technical complexity in our manufacturing program. Unlike cut-and-sew construction, seamless garments are produced on circular knitting machines that knit the garment as a three-dimensional tube, eliminating lateral seams entirely. The result is a garment with superior stretch uniformity, reduced skin friction, dramatically reduced chafing risk, and a cleaner visual aesthetic that aligns with the premium brand positioning most of our New York clients seek.
Seamless Knitting Technology:
Our seamless production uses 400-needle and 560-needle circular knitting machines capable of producing body-mapped compression zones within a single garment. This means the fabric density — and therefore the compression level — can vary across different regions of the same garment: higher compression through the waistband and side panels for sculpting support, lower compression across the bust zone for comfort, and medium compression through the leg panels for circulatory performance during training.
Customization in Seamless Construction:
In seamless construction, logo and design elements are integrated through knit-in patterns (the logo or geometric design is literally knitted into the fabric structure), jacquard knitting for color-blocked designs, or post-production silicone printing on the finished garment. Knit-in logos produce a subtle, premium-feel branding that is flush with the surface of the fabric — no raised edges, no heat application required, no risk of peeling or cracking over time.
Available Seamless Styles:
- Seamless high-waist leggings (knit waistband, full 4-way stretch body, compression leg panels)
- Seamless sports bra (built-in support structure, optional removable pads, knit-in design)
- Seamless long-sleeve training top
- Seamless short-sleeve top
- 2-piece and 3-piece matched sets
New York Style Gym Jackets & Performance Outerwear
Our jacket manufacturing program covers slim-fit performance outerwear designed to function as a coordinated set companion or standalone training garment. The most requested configuration among our New York clients is a slim-fit zip-front jacket in matching nylon-spandex fabric, providing consistent visual branding across a full 3-piece activewear set.
Technical Features Available:
- Full-length or half-length zip front with YKK-grade zipper hardware
- Thumb holes at the wrist cuffs (functional for training, popular for brand photography)
- Standup collar or mock neck construction
- Raglan sleeves for unrestricted shoulder mobility
- Mesh-lined side panels for ventilation during warm-up periods
- Side seam pockets with zip or open-top construction
- Logo placement: chest left, center back, sleeve, zip puller branding
Men's Performance Activewear
Beyond women’s gymwear, our New York manufacturing facility produces a full range of men’s and unisex performance activewear including:
- Men’s compression shorts and 5-inch training shorts
- Men’s jogger-cut training pants in nylon-spandex and polyester-spandex blends
- Unisex moisture-wicking performance t-shirts (120–170 GSM polyester / polyester blend)
- Men’s track and field shorts (lightweight polyester, 90–140 GSM, athletic fit)
- Unisex zip hoodies and performance sweatshirts
Premium Activewear Fabric Specifications — What We Use and Why It Matters for Your New York Brand
Fabric is not a commodity decision in activewear manufacturing. The blend ratio, GSM weight, knit structure, spandex elasticity rating, and finishing treatment of your fabric directly determine how your garment performs on the body, how it photographs, how it washes, and how long it retains its shape and compression properties. As a New York activewear manufacturer, we source only from mills with certified performance testing programs. Here is everything you need to know about the fabrics we work with.
Understanding Nylon vs. Polyester in Activewear Fabric
The two primary base fibers used in performance activewear are nylon (polyamide) and polyester (polyethylene terephthalate). While both are synthetic fibers capable of producing high-performance activewear fabric, they differ significantly in feel, performance characteristics, and manufacturing behavior.
Nylon (Polyamide) — Why It Dominates Premium Activewear:
Nylon is the preferred base fiber for premium activewear because of its exceptional softness, higher natural stretch elasticity, and superior recovery characteristics after repeated deformation. Nylon fiber has a rounder cross-section than polyester, which produces a smoother fabric surface with better light reflection — critical for the clean, flat visual appearance that brands producing leggings and sports bras demand. Nylon also has a lower pilling propensity than polyester under friction conditions, meaning garments hold their appearance through more wash cycles.
From a structural standpoint, nylon has a higher tensile strength-to-weight ratio than polyester, which allows manufacturers to achieve effective compression at lower GSM weights — important for warm-weather activewear where fabric weight affects wearability. Nylon also has a higher melting point during heat-finishing processes, which gives more latitude during silicone logo application and heat transfer branding without fabric distortion.
Polyester — Where It Excels:
Polyester is the preferred fiber for moisture management in high-volume perspiration applications. Polyester fiber has a lower moisture absorption coefficient than nylon — it wicks moisture more aggressively to the fabric surface where evaporation occurs — making it the technically superior choice for high-intensity cardio garments, men’s training tops, and performance t-shirts where sweat management takes priority over fabric softness. Polyester is also more colorfast under UV exposure and more dimensionally stable in high-heat wash cycles than nylon, making it the preferred choice for garments that will be laundered repeatedly at higher temperatures.
Our Fabric Lineup — Full Technical Specifications
Fabric 1 — 75% Nylon / 25% Spandex (Best-Selling Compression Blend)
This is our most requested fabric across all New York clients. The 75/25 ratio produces a fabric that balances compression force with stretch recovery — the spandex component (Lycra-grade elastane preferred) provides the elastic memory that returns the garment to its original shape after each stretch cycle. At 220–250 GSM, this blend delivers medium-to-high compression appropriate for leggings and sports bras targeting the mainstream fitness market.
Squat-proof opacity is achieved at 220 GSM and above in this blend when woven at standard warp and weft densities. We verify opacity on every fabric order using a standardized testing protocol: the fabric is stretched to 130% of its resting width (simulating the tension experienced at the hip and quad during a deep squat) and examined under a 1000-lux light source for any light transmission. Any fabric that shows measurable light transmission at this stretch ratio does not pass our opacity standard.
Recommended use: High-waist leggings, sports bras, coordinated 2-piece and 3-piece sets.
Fabric 2 — 78% Nylon / 22% Spandex (Sculpt and Compression Performance)
The 78/22 ratio shifts the mechanical balance slightly toward the nylon base, producing a denser fabric structure with a firmer hand feel and higher compression force per unit of stretch. The reduced spandex percentage means the fabric’s resting state is firmer, producing a more structured silhouette on the body — the sculpting effect that brands with aesthetic-focused positioning (contour seams, lift designs, body-shaping claims) typically require. This blend is our recommendation for high-waist leggings where the waistband must deliver significant abdominal compression without the use of additional stiffening panels.
Recommended use: Sculpt leggings, high-compression waistband panels, high-support sports bra body panels.
Fabric 3 — 90% Nylon / 10% Spandex (Premium Soft-Touch Seamless)
The 90/10 ratio is used exclusively in seamless and near-seamless garment construction where the priority is skin feel over structural compression. With only 10% spandex, the fabric’s elastic memory is moderate — it conforms to the body’s shape without aggressively compressing it — producing the “second skin” sensation associated with premium seamless activewear. This blend is significantly softer to touch than the 75/25 and 78/22 alternatives, and the higher nylon content produces a visibly smoother surface finish with better sheen retention after washing.
Recommended use: Seamless leggings, seamless bralettes, seamless tops, recovery wear.
Fabric 4 — Polyester / Spandex Blends (75/25 and 80/20)
Used for performance t-shirts, training shorts, unisex tops, and any garment where moisture management is the primary functional requirement. We source this blend at 120–170 GSM for tops and 90–140 GSM for shorts. The fabric undergoes a moisture-wicking finish treatment during the yarn processing stage (not a topical application that degrades with washing) ensuring the wicking performance is durable across the garment’s commercial life.
GSM Guide — Choosing the Right Fabric Weight for Your Activewear
GSM (grams per square meter) is the standardized weight measurement for fabric, and it is one of the most important specifications in activewear manufacturing. Here is how to think about GSM selection for your New York brand:
| GSM Range | Compression Level | Best Application | Opacity |
|---|---|---|---|
| 160–190 GSM | Light / minimal | Seamless bralettes, recovery wear, layering pieces | Marginal — not recommended for leggings |
| 200–220 GSM | Light to medium | Yoga leggings, low-impact training, warm-climate wear | Adequate — verified by stretch-opacity test |
| 220–250 GSM | Medium to high | Main legging and sports bra range — most brands | Excellent — best-seller range |
| 250–280 GSM | High compression | Sculpt/shape-focused leggings, postpartum recovery, high-support bra panels | Excellent |
| 280–300 GSM | Maximum compression | Specialized compression garments, therapeutic applications | Excellent |
Spandex (Elastane) Quality — Why the Source Matters
Not all spandex performs equally. The most significant performance differentiation in nylon-spandex activewear fabric comes from the quality and grade of the spandex component. Low-grade spandex loses elastic memory after repeated stretch cycles — the garment becomes baggy, the waistband droops, and the compression properties degrade rapidly with washing. Premium-grade elastane (Lycra-branded elastane from Invista being the industry benchmark) maintains over 95% of its elastic recovery force after 200 wash cycles and 10,000 stretch-recovery cycles.
We specify elastane grade in our fabric orders and can provide clients with fabric sample swatches for comparison before committing to bulk production quantities. For brands building products with premium positioning in the New York market, we recommend specifying Lycra-grade elastane explicitly in your tech pack — it is a meaningful quality differentiation that sophisticated consumers notice over time.
Partner with us — your reliable source for private label sports & gym wear manufacturing.
Complete Private Label and Custom Branding Services for New York Activewear Brands
Private label activewear manufacturing is not simply attaching your logo to a generic garment. True private label development means your brand’s identity is embedded throughout the garment — in the fabric construction, the silhouette engineering, the colorway selection, and the branding execution at every visible and tactile touchpoint. Here is the full scope of what we offer.
Silicone Logo and Branding Applications
Silicone printing is the most technically sophisticated and commercially desirable branding method currently used in premium activewear. Unlike screen printing or heat transfer vinyl, silicone is applied through a screen-printing process using a thermoset silicone ink that bonds molecularly with the fabric’s nylon fibers during a heat-cure stage. The result is a logo application that stretches with the fabric without cracking, peeling, or delaminating — even across thousands of wash cycles and high-intensity stretch events.
We offer silicone printing in two finish variants:
Matte silicone (most requested by NYC brands): Produces a flat, non-reflective surface that is nearly flush with the fabric — visible as a texture change rather than a raised embellishment. This finish is associated with premium, minimal brand aesthetics and photographs exceptionally well in flat lay and on-body shoot settings.
High-build (raised) silicone: Produces a palpable tactile embellishment — the logo has measurable height above the fabric surface. More visually prominent, used by brands seeking an assertive branding presence on waistbands and strap detailing.
Silicone logo sizing range: 3 cm to 15 cm width, single-color and multi-color available. Maximum printable logo detail: vector artwork recommended, minimum line weight 0.5 mm in final application size.
Heat Transfer Labels and Prints
Heat transfer technology covers two applications in activewear: brand graphics applied to the body of the garment (numbers, patterns, all-over decorative elements) and interior care/size labels applied to the inside of the garment to replace scratchy woven labels. Heat transfer care labels are our default recommendation for all activewear styles — they produce a clean, premium interior finish with no abrasion against the skin, which is a direct improvement to the wearing experience that consumers notice and remember.
Woven Labels, Hang Tags, and Retail Packaging
A complete private label garment is more than the garment itself. Every touchpoint — from the neck label to the hang tag to the polybag it ships in — communicates your brand’s quality level to the end consumer. We offer:
- Custom woven neck labels (branded + size designation, satin weave standard, damask weave for premium brands)
- Custom heat transfer size labels (seamless application, no skin contact irritation)
- Custom woven care labels (your brand’s care and content information, branded footer)
- Custom hang tags (single or double-card, hole punch + cord, full-color printing)
- Custom polybag packaging (branded logo print, biodegradable options available)
- Custom mailer box and tissue paper (for DTC brands with a retail unboxing experience)
Color Matching and Colorway Development
Color consistency across a multi-piece activewear set is one of the most technically demanding aspects of private label manufacturing. When a customer buys a legging and bra set, the two garments must be dyed to the same Pantone reference from the same dye lot to ensure a matching appearance. Variation between dye lots — even within the same nominal color — is visible in side-by-side comparison and represents a significant quality failure for premium brands.
Our color matching process uses Pantone Textile Color System (PTCS) references as the standard, with colorimetric spectrophotometer measurement on every dye lot to verify conformance to the target Delta E value (our tolerance is Delta E ≤ 1.0 for matched sets).
Standard colorway availability (no additional development cost):
- Jet Black
- Optical White / Bone White
- Mocha Brown
- Beige / Sand
- Slate Grey / Charcoal
- Navy Blue
Custom Pantone color development (available from 200 pieces per color):
- Olive Green
- Deep Brown / Espresso
- Dusty Rose / Mauve
- Sage Green
- Cerulean Blue
- Any Pantone TCX reference upon request
Tech Pack Development Support
A tech pack (technical specification package) is the master document that communicates every design, construction, and measurement detail of a garment to the production team. It includes flat sketches with construction notes, fabric specifications, BOM (bill of materials), graded measurement table, logo placement diagrams with size and position coordinates, colorway reference, and stitching specifications.
Many brands — particularly first-time founders in New York — come to us without a complete tech pack. We provide in-house tech pack development as a billable service, working from your reference images, mood boards, Pinterest collections, or verbal description. Our pattern makers translate your creative vision into a production-ready technical document. Tech pack development cost is credited in full against your first bulk order above 200 sets.
Size Grading, Inclusive Sizing, and Plus-Size Activewear For New York Users
Standard apparel sizing methodology scales a base pattern (typically a size Medium or size 8) up and down by adding or subtracting uniform increments from every measurement point. This approach produces technically accurate garments at the base size but systematically distorts garment proportions at the extremes of the size range — the reason plus-size activewear frequently fits poorly despite nominally covering the right measurements.
Our New York manufacturing team practices anatomically accurate grading — each size is graded with reference to the actual body proportion data for that size range, not simply scaled linearly from the base pattern. This means:
- The waistband height is increased proportionally for larger sizes to maintain the same visual waist coverage
- Hip curve and thigh width are graded independently from the waist, accounting for the reality that bust-to-hip proportions differ at different size points
- Inseam length is adjusted by size to maintain consistent 7/8 or full-length proportioning across the range
- Waistband width is increased for plus sizes to distribute compression force across a wider area without creating pressure concentrations that cause discomfort
We produce in the following standard size ranges:
- XS through XL (standard 5-size run — minimum recommended for a launch collection)
- XS through 3XL (7-size inclusive run — available with proper grading from our team)
- Children’s / youth sizing: 4/6, 6/8, 8/10, 10/12 (for junior activewear brands)
Plus-size specific technical features available: reinforced no-roll waistband with internal silicone gripper tape, extended waistband height (4–5 inches), reinforced inner thigh construction using higher-density fabric panel to resist abrasion, and strengthened gusset construction for expanded range-of-motion requirement.
Frequently Asked Questions – Private Label Activewear Manufacturer
What is the minimum order quantity for custom activewear manufacturing in New
Our minimum order quantity for bulk production is 50 sets per style for standard catalog designs using our in-stock fabric range. For custom colorways (Pantone-matched dye lots), the minimum increases to 100–150 sets per style due to minimum dye lot requirements at our partner textile mills. Seamless styles have a minimum of 100 pieces due to circular knitting machine setup costs. Sample development can be initiated with 1 to 3 pieces per style with no minimum quantity requirement.
How long does custom activewear manufacturing take from start to delivery in New York?
The complete process from initial briefing to delivery of bulk production typically takes 6 to 9 weeks. This breaks down as: 2–3 days for quotation, 7–14 days for sample production, 5–10 days for sample review and approval, 7–10 days for bulk fabric procurement, 15–20 days for production, 3–5 days for QC and finishing, and 3–7 days for delivery to New York. Rush production is available at a premium for orders within our existing production schedule.
What fabrics do you use for custom leggings manufacturing in New York?
Our primary fabric for leggings and sports bras is 75% Nylon / 25% Spandex at 220–250 GSM — the most widely requested blend among our New York clients. We also manufacture in 78% Nylon / 22% Spandex (higher compression and firmer hand feel for sculpt-focused designs) and 90% Nylon / 10% Spandex (premium soft-touch for seamless construction). All fabrics are sourced from mills with verified squat-proof opacity ratings at stretch — we test all fabrics using a standardized 130% stretch opacity protocol before committing to a production run.
Can you manufacture plus-size activewear with proper grading in New York?
Yes. Our New York manufacturing team practices anatomically accurate grading — not linear scaling — for sizes XS through 3XL. For plus-size styles, we engineer specific technical features including reinforced no-roll waistbands with internal silicone gripper tape, extended waistband height, reinforced inner thigh panels, and strengthened gusset construction. We do not simply scale a size 8 pattern to a size 20 and call it inclusive sizing.
What branding options are available for private label activewear manufacturing?
We offer matte silicone logo printing (our most popular option — premium, stretch-compliant, durable), high-build silicone printing, heat transfer labels, woven neck labels, heat transfer care/size labels, embroidery, custom hang tags, and branded packaging. Silicone printing is recommended for placement on legging waistbands, sports bra underbands, and strap elements — it stretches with the fabric without cracking or peeling across repeated wash and wear cycles.
Do you manufacture activewear for children and youth sizes in New York?
Yes. We manufacture youth and children’s activewear in sizes 4/6, 6/8, 8/10, and 10/12 in styles including sports tops, form-fitting shorts, skirts with built-in leggings, and training jumpsuits. All children’s garments are manufactured using the same performance fabrics as our adult range — Nylon/Elastane and Polyester/Elastane blends conforming to relevant safety standards for children’s clothing.
What is the difference between OEM and ODM activewear manufacturing?
OEM (Original Equipment Manufacturer) means we produce your garment to your exact design specifications — you provide the tech pack, the design, and the branding, and we manufacture it. ODM (Original Design Manufacturer) means we develop the design in collaboration with you — you provide a brief, reference images, or a concept, and our design and pattern team develops the full technical specification. Both OEM and ODM services are available at our New York manufacturing studio, with tech pack development charged as a billable service credited against your first bulk order.
Do you ship custom activewear orders to countries outside the US?
Yes. While many of our clients are based in New York and across the United States, we regularly ship to brands in the United Kingdom, Spain, Germany, Costa Rica, Mexico, Brazil, and the Middle East. International shipping is handled via DHL Express, FedEx International, and freight consolidators for larger orders. All garments are shipped with commercial invoices and packing lists conforming to customs requirements in the destination country.
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MOQ, Pricing Structure, and Production Timelines — Full Transparency for New York Brands
We believe every brand founder deserves complete transparency about what manufacturing actually costs and how long it actually takes before they make a commitment. Below is our full breakdown, structured honestly to help you make the right decision for your brand at its current stage.
Minimum Order Quantities (MOQ) Explained
Our MOQ structure is tiered by production type and customization complexity:
| Production Type | MOQ | Notes |
|---|---|---|
| Sample development (pre-bulk) | 1–3 pieces per style | Required before bulk commitment |
| Bulk — standard styles (catalog) | 50 sets per style | Available in our standard fabric and colorway range |
| Bulk — custom fabric / colorway | 100–150 sets per style | Custom Pantone colors require minimum dye lot |
| Bulk — fully custom design (new pattern) | 100 sets per style | Includes new pattern development fee |
| Seamless production | 100 pieces per style | Circular knitting machines have higher setup cost |
We make no pretense that our MOQ is “the lowest in New York.” What we offer is the lowest MOQ at which we can maintain the quality standards our brand clients need. Producing 20-piece orders creates quality inconsistency across the run because the fabric cutting efficiency, thread tension calibration, and quality control sampling rate all deteriorate below the 50-unit threshold. Our MOQ protects your product quality, not our margin.
Sample Development — Cost, Process, and What You Receive
The sample development stage is the most important stage of your brand’s manufacturing relationship with us. It is where garment fit is validated, fabric performance is verified in the physical garment, branding placement is confirmed, and any construction issues are identified and corrected before they are multiplied across a 500-unit bulk run.
Sample development includes:
- Tech pack review and production-feasibility assessment (we identify any specification that will be difficult or impossible to execute as drawn and propose alternatives)
- Fabric sourcing — we source the exact fabric specification from our mill network and send you a physical swatch for approval before cutting the sample
- Pattern development — if your design requires a new pattern (not a modification of our catalog base patterns), our pattern maker develops a production-grade pattern including all size markings
- Sample cutting and sewing — the first physical garment in your size (typically a Size S or M for women’s)
- Branded finishing — silicone logo, labels, and packaging applied exactly as specified in your tech pack
- Delivery to your New York address or shipping address of choice
Sample cost range: $80 to $250 per style depending on construction complexity, fabric requirements, and branding complexity. Sample costs are credited against your bulk order above 150 sets.
Sample turnaround: 7 to 14 business days from tech pack approval and fabric swatch sign-off.
Bulk Production Timelines
| Stage | Timeline |
|---|---|
| Tech pack review + quotation | 2–3 business days |
| Fabric swatch approval | 2–5 days (dependent on client) |
| Sample development | 7–14 business days |
| Sample review and approval | Client-controlled (we recommend 3–5 days) |
| Bulk fabric procurement | 7–10 business days after approval |
| Bulk cutting and production | 15–20 business days |
| Quality control and finishing | 3–5 business days |
| Packing and shipping | 2–3 business days |
| Total from tech pack to delivery | Approx. 6–9 weeks |
We do not compress production timelines on request at the expense of quality. Rush orders (under 4 weeks total) are available at a 20–30% premium for orders that fit within our existing production schedule — contact us to enquire about current capacity before booking a rush timeline.
Bulk Pricing Structure
We do not publish per-unit prices publicly because the cost of a garment is determined by a minimum of six variables: fabric blend and GSM, construction complexity, customization level, quantity, colorway count, and size run. A 75% nylon legging at 220 GSM with a standard waistband and single-color silicone logo at 200 units per color is a fundamentally different manufacturing cost than a 78% nylon seamless legging with body-mapped compression zones, two-color knit-in branding, and Pantone-matched custom colorway at 100 units.
What we can confirm:
- Our pricing is competitive with comparable-quality manufacturers globally, with the significant advantage of NYC-accessible development support and faster resolution of quality issues
- We provide itemized quotations that break down fabric cost, cut-and-make cost, branding cost, and packing cost separately — so you understand exactly where your production dollar is spent
- Volume pricing scales meaningfully: the per-unit cost at 500 sets is typically 20–35% lower than the per-unit cost at 100 sets
- Payment terms: 50% deposit at order confirmation, 50% balance before shipment (standard); letter of credit available for established clients with order history
New York Activewear Brands We Manufacture For — Our Ideal Clients
We are selective about the partnerships we take on because quality manufacturing requires genuine collaboration. The clients we work with most successfully fall into these categories:
First-Collection Brand Founders in New York: Entrepreneurs launching their first private label activewear line, typically starting with 50–150 sets per style in 1–2 colorways. We guide this client type through the entire manufacturing process from fabric selection to delivery, providing the technical expertise they have not yet had the opportunity to develop. Many of our longest-standing client relationships began with a 100-set first order.
Scaling Fitness Brands: Brands that have already validated their product-market fit with an initial production run and are now expanding into new styles, new sizes, or new colorways. We provide the production capacity and technical consistency to scale without compromising the quality that earned the brand its initial customer base.
Fashion Designers Entering Activewear: Apparel designers with strong aesthetic vision and pattern-making knowledge who are new to performance fabric and activewear-specific construction requirements. We provide technical translation — converting fashion design intent into activewear-appropriate construction specifications.
Fitness Influencers and Athlete-Founded Brands: Individuals with an established audience and a strong product concept who need a manufacturing partner, not just a factory. We provide the branding sophistication and low MOQ accessibility that makes a first product launch viable.
Inclusive Activewear Brands: Founders specifically building brands for plus-size, postpartum, or body-positive markets who require proper anatomical grading, reinforced construction, and technical features appropriate for the bodies they serve.
International Brands Needing US-Based Manufacturing Support: Brands based outside the US that want New York-accessible production support for the American market — faster domestic shipping, US-compliant labeling (FTC fiber content and care labeling requirements), and a manufacturing partner operating in the same time zone as their US customers.
Start Your Custom Activewear Manufacturing Project in New York — Request a Free Quote Today
Whether you are a New York brand founder preparing to launch your first activewear collection, a fitness entrepreneur who has outgrown your current manufacturer, or an international brand seeking US-based production support — the next step is the same: tell us what you need.
Our team of New York activewear manufacturing specialists responds to all quote requests within 24 hours with a preliminary assessment, fabric recommendations, and a realistic timeline for your project.
There are no minimum quote requirements, no obligations, and no cost to the consultation. Share your idea — we will tell you exactly what it takes to manufacture it.