Custom Activewear Development for a Fitness Brand (USA Client)
Recently, we’ve been working with a fitness brand from the US on developing a custom activewear collection.
The client already had a clear direction for the products, including reference styles, sizing requirements, and branding details. Most of the discussion in the beginning was actually around fabric feel, fit, and how the final pieces would perform during training.
For activewear, fabric is one of the most important parts. Stretch, comfort, thickness, breathability — even small differences can completely change how the product feels when worn.
We started by sourcing several fabric options and comparing them based on the client’s requirements. Some fabrics looked good visually but didn’t feel right when stretched. Others were comfortable but too thin for the positioning the client wanted. So there was quite a bit of back-and-forth during this stage.
After confirming the fabric direction, we moved into sample development.
One thing we paid extra attention to was sizing and fit. Activewear is very different from regular clothing — customers expect it to fit closely while still being comfortable during movement. Small measurement differences can become very noticeable once the garment is worn.
We worked closely with the factory to double-check measurements, stitching details, logo placement, and overall construction during sampling.
At the same time, we also helped coordinate some of the branding details such as labels, logo applications, and packaging ideas.
During the process, we kept updating the client through photos, videos, and measurement checks so adjustments could be made early before production.
For us, projects like this are never just about “finding a factory”.
A lot of the work is really about communication, details, problem-solving, and making sure the final product matches what the client originally imagined.
The project is still moving forward, and we’re currently preparing for the next production stage after final sample confirmation.
