Activewear fabric guide: choosing fabric for leggings, sports bras and yoga wear
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Which fabric should I choose for activewear?
Most activewear is knitted from nylon or polyester blended with spandex, also called elastane. Nylon blends tend to feel smoother and softer and resist abrasion well; polyester blends usually cost less, dry quickly and suit sublimation printing. Choose by what the garment has to do, and confirm weight, stretch, recovery and opacity on a physical sample before bulk.
Nylon/spandex or polyester/spandex?
| Nylon/spandex | Polyester/spandex | |
|---|---|---|
| Hand-feel | Smooth and soft, often cool to the touch | Varies widely; brushed finishes can feel very soft |
| Durability | High abrasion resistance | Good abrasion resistance and colourfastness |
| Moisture | Absorbs a little more water, so dries more slowly | Absorbs very little water and dries quickly |
| Printing | Printed with dyes made for nylon; not suited to sublimation | Suits sublimation printing |
| Cost | Usually higher | Usually lower |
| Common uses | Premium leggings, sports bras, swimwear | Training wear, printed styles, everyday activewear |
Properties vary with the yarn, the knit and the finish, so treat this as a starting point and judge the actual fabric on a sample.
What does spandex do?
Spandex, also sold as elastane or under brand names, gives fabric its stretch and recovery. A higher spandex share gives more compression and hold; a lower share feels lighter and less restrictive. Ask for the exact composition on the fabric specification, because the same fabric name can cover quite different blends.
Single jersey or double knit?
Single jersey is a light knit with a smooth face and a looped back, used for tops and lighter garments. Double-knit fabrics such as interlock are thicker, more stable and more opaque, which is why many leggings use them. Ask for the fabric weight, and test opacity while the fabric is stretched, not only when it lies flat.
What is seamless knitting?
Seamless garments are knitted as a tube on circular knitting machines, so they need few or no side seams. Rib, mesh and compression zones are knitted into the garment rather than sewn on. Seamless development depends on machine programming, so ask how changes to a seamless design are sampled.
Do performance finishes last?
Moisture-wicking, quick-dry, anti-odour and brushed effects can come from the yarn, the knit structure or a chemical finish. Finishes applied after knitting can fade with washing, while properties built into the yarn or the structure usually last longer. Ask which one you are getting, and wash-test a sample before approving bulk.
What about recycled fabrics?
Recycled polyester and recycled nylon are available in activewear weights and blends. If you plan to make a recycled claim on your label or website, ask for the supporting documentation for that specific fabric and keep it on file.
What should you test on a fabric sample?
| Test | What to look for |
|---|---|
| Squat or stretch test | Stretch the fabric over a knee or a fist in good light and check that it does not turn see-through. |
| Recovery | Pull the fabric in both directions and check that it springs back without bagging. |
| Washing | Wash it several times and look for pilling, shrinkage and colour change. |
| Colour transfer | Rub a dark colour against a white cloth and check for staining. |
| Seams and waistband | Stretch the seams and waistband and check for popped stitches or rolling. |
How Jojofashion works with these fabrics
| Fabrics | Fabrics we work with: polyester/spandex and nylon/spandex single and double jersey, performance fabrics (moisture-wicking, stretch and shaping), recycled fabrics, scuba/air-layer, rayon/spandex, cotton, denim, and woven lining fabrics for bags. |
| Main categories | We manufacture knitted activewear — yoga wear, seamless, and leggings. |
| Other categories | We also produce casual wear, dresses and womenswear, swimwear, and padded jackets and outerwear. |
| Sampling time | Sampling takes around 7 days. |
| Seeing samples | We have a showroom in California, USA, where samples can be viewed in person. |
Each line in this table is quoted from our verified fact register.
Frequently asked questions
Is nylon or polyester better for leggings?
Neither is better in every case. Nylon/spandex is often chosen for soft, smooth premium leggings; polyester/spandex is often chosen for printed or price-sensitive styles. Judge the specific fabric on a sample for opacity, stretch and recovery.
How do I stop leggings from being see-through?
Choose a denser knit such as a double knit, ask for the fabric weight, and test the sample by stretching it over a knee or doing a squat in good light. Light colours show more than dark ones, so test light colours separately.
Can activewear be made from recycled fabric?
Yes. Recycled polyester and recycled nylon blends are available for activewear. Ask for the documentation that supports any recycled claim before printing it on labels or in marketing.