Custom Yoga Wear Manufacturer — Leggings, Bras, Tops & Outerwear
OEM & ODM yoga apparel for studio brands, fitness studios, wellness retailers and influencers in 30 countries. In-house knitting, cut-and-sew, sublimation and QC — from sketch or tech pack to labelled, packed cartons.
Fexwear is a custom yoga wear manufacturer producing OEM and ODM leggings, sports bras, yoga tops, outerwear and accessories for studios, wellness brands, boutique gyms and retailers in 30 countries. Founded in 2010, we run our own in-house knitting, cut-and-sew, sublimation and quality-control lines, and we take a yoga programme from a rough sketch or a finished tech pack all the way through to labelled, packed cartons — with minimum order quantities starting at 10 pieces.
Yoga wear sits in a strange place between performance apparel and everyday clothing. It has to survive a hot yoga class where the fabric gets soaked in sweat and stretched through a ninety-minute sequence, and it also has to look good in a coffee shop afterwards, because that is where most of its wearers actually spend their time. That dual requirement is what makes yoga construction different from gym construction, and it is why fabric weight, drape and seam placement matter more here than in almost any other activewear category.
This guide covers what we actually run: the product families, the fabric constructions that make them work, the construction and decoration decisions behind a clean studio look, sizing and fit, minimum order quantities and pricing, private label packaging, and the questions buyers ask most. It is written for people making a buying decision.
Custom Yoga Apparel We Manufacture
Four core product families, all produced in-house with your artwork, colours and labels.
Bras & Tops
Sports bras, bralettes, scoop-neck tanks, crop tops and long-sleeve fitted layers. Engineered stretch knits with a second-skin hand and enough structure to hold shape through a heated class, in sizes from XS to 3XL.
Jackets & Coverups
Hoodies, gilets, zip jackets, capes and open coverups for the studio lobby and the walk home. Brushed fleece, French terry and lightweight water-resistant shells in sizes that layer over a sports bra without bulk.
Bottoms
Full-length leggings, capri leggings, bike shorts, wide-leg pants and skirts. High-rise and mid-rise waistbands, four-way stretch with strong recovery, and a knit weight that stays opaque in a deep forward fold.
Accessories
Strap bags, headbands, wristbands, socks and mat carriers. Small items that complete the set and lift basket value without a second supplier.
Performance fabrics
Four-way stretch knits with a bare-skin hand, quick-dry and moisture-wicking finishes, anti-pilling and anti-chafe treatments, chosen for drape as much as for recovery.
Customized labels
Heat-transfer woven labels, sublimated tags, screen-printed neck prints and woven size tabs, produced in-house so label minimums never stall your launch.
Pantone matching
Fabrics dyed to your exact Pantone reference and checked against a physical swatch under daylight, so the colour you approved is the colour that ships.
Sublimation labels
Zero-lineage labels that bond into the fabric with no stitch mark and no printed edge, in unlimited colours with no minimum quantity.
Yoga Fabric Specifications: Weight, Composition and Drape
Nylon-spandex: the premium legging construction
Nylon 82 / Elastane 18
The standard for premium studio leggings. Nylon has a softer, more expensive hand than polyester and better recovery, which is why it holds a smooth surface through a long wear day. The elastane versus nylon trade-off is worth reading before you commit: above roughly 20% elastane the fabric gets grippy and matte but loses snap-back over time, below 15% it feels slick at first and bags out sooner. 18% is the balance most of our studio clients choose.
Brushed-back and peached finishes
Brushing on the inside face gives a warm, matte, almost velvet hand that reads as premium and hides seam lines. It also reduces airflow slightly, so brushed-back leggings work better for vinyasa and restorative classes than for hot heated yoga. If your customer is doing ninety-minute hot yoga, keep the finish light.
Polyester-spandex: the studio workhorse
Polyester 78 / Elastane 22
Lighter and cheaper than nylon, with excellent colour availability and easy access to recycled versions. 150 gsm is the right weight for summer studio leggings and for anyone who runs hot; 220 gsm has more opacity and structure for a smoother silhouette. More detail on fabric types for custom sportswear in the full guide.
Interlock and ribbed knits
Interlock is the right structure for fitted tops and sports bras because it lies flat and resists curling. Ribbed knits with a higher elastane content give a second-skin compression fit that holds its shape, and rib texture also hides minor waistband and hem lines. For crop tops and bralettes, rib with 18–22% elastane is the most forgiving construction to sell at scale.
Tulle, mesh and open-weave
Mesh panels, tulle overlays and open-weave fabrics are used for cutouts and layering effects. They need a different approach to grading because they grow when cut, and they show every seam behind them. If a design uses mesh, we recommend a contrast binding at every raw edge rather than a turned hem, which is the usual failure point.
Spandex and elastane blends worth knowing
Nylon-spandex
Best hand and recovery, premium price, best for studio and lifestyle.
Polyester-spandex
The cost-effective default, widest colour range, easiest recycled sourcing.
Spandex cotton blends
Soft and matte, comfortable for low-impact classes, but they pill at the hip and seat and absorb sweat. Keep cotton under 10% for a performance line.
Tencel / Lyocell blends
Drape-forward with a cool hand and good moisture management. A good choice for a more fashion-led yoga line. Our fabric selection guide covers how to spec these without over-ordering on the wrong weight.
Outerwear fabrics
Finishes worth specifying
Moisture-wicking finish
Pulls sweat into the fabric rather than leaving it on the skin. Standard on most performance knits, but specify it explicitly.
Anti-pilling finish
Important for fleece and terry, which is where pilling shows first on the waist and cuff.
Anti-chafe finish
A softener treatment on the inseam and waistband that reduces friction in long holds and inversions. Cheap to add, and it measurably reduces returns on leggings.
UV protection
UPF 40+ for outdoor and beach-yoga lines.
Environmentally certified fibres
Recycled polyester (rPET), recycled nylon or bio-based elastane. We hold BSCI, WRAP, SEDEX and SMETA for labour and social audit, OEKO-TEX for material safety, and ISO-based quality management. If retail compliance needs documented sustainability credentials, ask which certificate covers which fabric.
Construction & Decoration Details
Seam-free and flatlock construction
Where seams are unavoidable — around the gusset, or on a panelled design — the join should be flatlock or coverstitch, which sits flat against the skin. A conventional overlock leaves a ridge, and in yoga that ridge is felt in every forward fold and every long hold. Our sewing stitch guide covers the options in more detail.
Waistbands
Crotch gusset
Any legging intended for yoga should have a gusset. A diamond or contoured gusset in a contrast colour or a matching tone removes the centre seam from exactly where the garment takes the most stress, and it is the detail that most reliably separates a studio legging from a generic one. This is a low-cost decision with a high visible return.
Necklines and armholes
Bound necklines with a fine jersey binding read far more expensive than a raw cut edge, and they will not unravel if the customer stretches the neckline putting it on. For scoop and crew necks, specify the binding width (3–5 mm is the usual fine finish). For racerback and open-back designs, the armhole binding is the detail that decides whether the piece looks intentional.
Printing on yoga fabrics
- Best for
- Solid-colour logos, text and high-opacity graphics
- Why
- Cost per unit drops sharply above a few hundred pieces, and it is the right choice for chest prints, wordmarks and studio logos on the back of a top
- Best for
- All-over prints, photographic panels and gradient-heavy graphics
- Why
- Ink bonds with the fabric under heat and pressure, so it becomes part of the garment rather than sitting on top — will not crack, feels soft
- Limit
- Requires polyester-dominant fabric. Full comparison in our printing methods guide
- Best for
- Outerwear, headbands, and the small logo of a sports bra strap
- Why
- Classic premium detail that reads as considered branding
- Limit
- On high-stretch fabric, specify a light thread weight and a backing behind the stitch so it does not puck
Branding and trims
Heat-transfer woven labels
Our usual route for woven-looking labels at low minimums.
Sublimated labels
Printed flat labels with unlimited colours, zero stitch lines, no minimum. On yoga specifically this is the premium choice, because the no-lineage finish is invisible against a bare-skin fabric.
Screen-printed neck print
A size or brand mark inside the neck, effectively free and completely standard for retail.
Silicone logo and woven badges
For outerwear and accessories where the branding is the point.
Sizing, Fit and Grading
Build a real tech pack
A tech pack that actually gets sampled first time needs measurement charts, not just garment images. Minimum we need: body measurement chart by size, finished garment measurements, and the intended fit described in words. Our sizing and measurement blueprint walks through building one from scratch.
Choose a fit, then hold to it
Compression / studio fit
Skims the body, higher elastane, sized close to the body. The most flattering in a studio and the least forgiving across a wide size range.
Standard retail fit
Follows the body with a small ease allowance. The safest choice for first runs and for marketplaces where the size chart is all the buyer sees.
Relaxed / lifestyle fit
Deliberate ease, appropriate if you are building a brand that transitions from studio to street. Many buyers start here deliberately, because a relaxed piece sells to a wider audience than a compression piece.
Whichever you choose, decide before sampling and do not drift between fits across a drop. If crop and full-length pieces ship together, derive both from the same blocked pattern so they match at the waistline.
Grading a stretch knit
Size runs and inclusivity
Standard grading follows XS to 3XL with roughly 4–5 cm chest and waist increments, but for yoga the waist and hip often need more aggressive increments than the chest. If you are building a brand aimed at plus-size or petite customers, say so at the design stage — those customers need a different block, not just extended sizes, and a sports bra and leggings programme is where block design matters most.
Quality Control and Compliance
In-line and final inspection
Inspection runs at three points. In-line inspection checks cut panels against the size set as they are laid, which catches grading errors before they become sewn panels. Seam and binding checks run during sewing, catching skipped coverstitch, unpicked binding and missed bar tacks. Final inspection is a full AQL pass on the packed cartons, checking measurements, workmanship, labelling and packaging.
Stretch, opacity and wash testing
Physical & opacity tests
- Stretch recovery test — stretch and release each fabric, measuring residual deformation. Under 3% residual is our floor for a legging that holds its shape.
- Light table opacity test — stretched, and also with two layers overlapped to simulate a forward fold.
- Burst and tear test — focused on the gusset and any panelled seam, which are the highest-risk joinery points in a legging.
- Dimensional stability — sample garments are washed and re-measured. This is the test that catches the label that shrinks and the waistband that relaxes.
Colour, surface & packing
- Colour fastness to wash and sweat — sublimated prints are tested to confirm the ink does not migrate or fade under sweat and detergent.
- Pilling test — rub testing on fleece and terry, which is where pilling appears first on the waist and cuff.
- Retail-ready packing — folded to size, polybagged, tagged with your size and care labels, and barcoded with GTIN or UPC as required. Studios and retailers have their own packaging requirements, and we can produce retail-ready packing to their spec. Yoga packaging tends to be simpler and smaller than gym packaging, so tell us your studio or retailer in the first enquiry and the packing spec will be built in from the start.
Minimum Order Quantity, Pricing and Volume Tiers
MOQ from 10 pieces
Two things routinely push a project above the floor: size ratio and colour count. A style in five sizes with three colourways is fifteen combinations, so the practical minimum is ten pieces in each. For a first collection, the efficient split is ten pieces across three styles rather than forty of one, because it gives you real feedback on three products.
What actually drives unit price
Nylon-spandex at 190 gsm is roughly double the cost of a poly-cotton blend at the same weight, before finishing.
A circular-knit seamless legging costs materially more than a cut-and-sew equivalent, and it is the main reason seamless pieces sit in a higher price tier.
Contour waistbands with drawcords, gussets, bound necklines, mesh panels and lining each add a setup and a sewing operation.
An all-over sublimated panel costs more than a chest screen print, but the per-unit cost falls as coverage rises.
A five-size run costs more per piece than a two-size run because setup time and panel changes both grow.
A branded woven label adds real cost at low volume; sublimated tags add almost nothing.
Volume tiers
The drop in unit price happens in steps, not smoothly, and the biggest step is usually at a few hundred pieces per style. The wholesale buyer guide covers how buyers structure tiers and where the real breakpoints fall. Practical advice: get the fabric and fit approved on a sample, then order your first real run in the sizes you actually sell, not a size set that looks balanced on paper.
Private Label, OEM and ODM
What the private label package includes
ODM versus OEM
You supply the design, fabric specification and artwork; we manufacture to it. The right choice when you already have a proven product and want to scale it.
You choose from our existing library of constructions and we adapt them to your brand. Faster and cheaper for a first run, and lower risk if the product is untested, but the fit and fabric are ours rather than yours.
Most first-time studio brands start with ODM to validate demand, then move the winners to OEM. If your line overlaps with gym wear or activewear, the same block often serves both, which reduces your development cost across the range. Our yoga wear due-diligence guide covers what studio buyers actually check when they compare you on landed cost, not just unit price.
Order Timeline: Enquiry to Delivery
Working backwards from a launch date
We review your design, confirm the fabric, give a costed quote and confirm what is achievable at your quantity.
From sketch to sample: you send artwork or a sketch, we produce a sample for approval. Allow three to five days for a standard sample, longer for a seamless or heavily panelled one.
Samples come back with your written approval. Fit changes after approval mean a second sample, so it pays to be specific in the first round.
Knitting, cutting, sewing, printing and finishing. Two to four weeks is typical for a moderate order; complex multi-style programmes run longer.
AQL inspection, packaging, and dispatch. Air freight is around a week; sea freight to Europe or the US runs three to five weeks.
Plan on roughly ten to twelve weeks from enquiry to delivery for a standard programme, and add two to three weeks if you are launching into a season with a fixed date. If your date is immovable, tell us in the first conversation — we would rather decline a rushed order than ship something that arrives without time for your own quality check.
Custom Yoga Clothing Suppliers
Our capabilities
- Professional expertise — a dedicated production team for yoga and activewear categories.
- Customization specialists — experience across custom sportswear, running apparel, studio uniforms and sublimated pieces.
- Cost-effective solutions — long-term partnerships across material sourcing, production, label manufacturing and shipping.
Service & quality
- Comprehensive OEM & ODM services — sublimation patterns, design support, sampling, logos, labels, packaging and shipment.
- Premium materials — access to a wide library of performance fabrics, BSCI test certified.
- Quality assurance — a dedicated QC team conducting three rounds of inspection.
- Efficiency and flexibility — fast turnaround, low MOQ, and a clear willingness to tell you when a design will not work as drawn.
With Fexwear, you can establish or expand a yoga brand in the USA, UK, Canada, Australia and beyond. We help bring your vision to life within a few months, and we help you build a yoga wear brand that survives due diligence from buyers who compare you on landed cost, not just unit price.
Start Your Custom Yoga Wear Order
Tell us your style, fabric, quantity and delivery date, and we will come back with a costed quote and an honest read on what is achievable at your volume. We will also tell you if we are not the right fit for the job.
Frequently Asked Questions
What is your minimum order quantity for custom yoga wear?
Minimum order quantities start at 10 pieces per style and colour, which makes first collections genuinely small. Remember that MOQ is per design, not per order, so you can run several styles at ten pieces each. Practical minimums rise once you add a five-size run or three colourways.
Can you make seamless leggings?
Yes. Circular-knit seamless leggings are knitted as a tube with no side seam, with the waistband knitted in or joined at a low-profile point. They cost more than a cut-and-sew equivalent and lead time is longer, so they are usually worth reserving for a proven product rather than a first sample. For first runs, flatlock-seamed leggings give a very similar visual result at a lower cost.
Are your fabrics squat-proof and opaque in a forward fold?
We test every fabric on a light table, stretched and also with two layers overlapped to simulate a forward fold. For pale and mid-tones we recommend a skin-tone backing behind the garment. We will not label a fabric as squat-proof if it fails the test, and we will show you the swatch before you commit.
Can I mix sizes and colourways within one order?
Yes. You can mix sizes within a colourway and mix colourways within a style. The constraint is that each design-colour combination needs to meet the minimum quantity, so within a fixed budget the lever is to raise the quantity on one colourway rather than split a small order across many.
Do you match Pantone colours?
Yes. We dye to your Pantone reference and check against a physical swatch under daylight viewing, because monitor colour is the most common source of disputes. Saturated and neon shades can shift slightly between dye lots, so for those we recommend a lab dip or a larger colour block before bulk.
What artwork file format do you need?
Vector files — AI, EPS or PDF — give the best results and let us scale artwork to any panel without loss. For sublimation all-over prints, a high-resolution raster file at 300 dpi at final size is acceptable. We will confirm resolution requirements when we see the file, and we can work from a rough sketch if you are early in the process.
How long does sampling take?
Three to five working days for a standard sample. Seamless and heavily panelled constructions take longer because they need separate tooling and longer knitting runs. Sample cost is credited against your first bulk order.
Do you offer recycled or sustainable fabric options?
Recycled polyester (rPET), recycled nylon and bio-based elastane options are available on request. If recycled content is part of your brand positioning or a retail buyer requirement, flag it early, because documentation and certification lead times add to the schedule. We hold BSCI, WRAP, SEDEX and SMETA for labour and social audit, OEKO-TEX for material safety, and ISO-based quality management.
Can you ship to our country?
We ship to 30 countries and can arrange both air and sea freight. We produce retail-ready packaging and barcodes where your market requires them. Tell us the destination and your retailer’s requirements in the first enquiry so packaging is built in from the start.
Can I reorder the same line next season?
Yes, and reorders are the easiest part of the process. If the fabric is stocked or routinely sourced in our in-house production, lead times are predictable and reorders match the original run. We keep your pattern, trims and artwork on file, and we hold block patterns and trims so a repeat order lands on the same fit.
Contact Us
Contact Us
|
|