Look, I didn’t come here to write some glossy catalog piece. I’ve got lint in my boots and a coffee stain on my last QC report from Dongguan. You want a guide? Fine. But this isn’t for fashion bloggers or Instagram influencers who think “sustainable” means using green ink on their packaging. This is for the people who actually make stuff—startup founders burning midnight oil over Alibaba messages, boutique brand owners sweating their first MOQ, sourcing managers trying to keep retailers happy without going broke.
You came for a list of shorts. Okay. There are 28 types out there, sure. But if you’re serious—and I mean factory-floor serious—you don’t care about all of them. You care about what sells, what survives washing, and what doesn’t get returned because the seams blew out after one squat session.
So let’s cut the fluff.
Athletic Shorts
This is where it matters. Where fabric meets function. Where your reputation gets built—or torched.
I was in a factory in Ningbo last winter, standing next to a roll of so-called “performance” mesh that looked like fishnet and performed worse than cotton twill. The buyer had gone cheap. $1.30/yard. No stretch recovery test. No GSM check. Three months later, they ate 14% returns on running shorts because the side seams kept splitting during high-impact runs.
That’s not a typo. Fourteen percent.
At Fexwear, we had a batch last summer where we caught exactly that kind of failure in a mid-line audit—turns out the sewing operator skipped the double-needle reinforcement on the inseam. We killed the run. Recut. Re-ran. Cost us three days and $8K. But the client didn’t lose face with their retailer. That’s the difference between surviving and disappearing.
Running Shorts
Lightweight? Sure. But lightweight doesn’t mean fragile. If you’re making running shorts under 150 GSM, you better be damn sure about your fiber blend.
Here’s what no one tells you: polyester alone purls like hell after six washes. You need spandex—but not too much. We tested 89 blends across 14 sports categories (yeah, I counted), and the sweet spot for running shorts is 80% polyester, 20% spandex. Textured yarns help wicking. Flatlock stitching reduces chafing. And for god’s sake, use a 4-thread overlock, not 3.
One of our buyers—a small Shopify store doing urban fitness gear—went with a 70/30 blend thinking more stretch = better comfort. It wasn’t. After two months, return rates spiked. Customers said the shorts “lost shape” and “felt saggy.” We pulled samples, ran recovery tests: only 86% rebound after 10 cycles. Industry standard is 95%. That 9% gap cost them $22K in unsellable inventory.
Don’t be that guy.
And if you’re sourcing fabric, go to Fexwear’s fabric recommendations page —not because I’m pushing it, but because we’ve got real data on moisture management, RET scores, and spandex degradation timelines. It’s not theory. It’s what we use when someone says, “Make me the best damn running short that won’t fall apart before race day.”
Hiking Shorts
Pockets. Everyone thinks hiking shorts are about durability. Nah. They’re about pockets. And ventilation. And whether the guy wearing them can piss behind a tree without taking everything off.
We had a client from Colorado—nice guy, ex-Navy, started a trail brand. Wanted rugged, military-grade material. So we went with 210D ripstop nylon. Heavy. Tough. Looked like armor.
First field test? Guy sat down on a damp log. Couldn’t feel his ass for 45 minutes. Fabric didn’t breathe. Sweat pooled. One hiker developed a rash. Another said, “Feels like I’m wearing a tent.”
Back to the drawing board.
We switched to a 98/2 blend: recycled polyester with 2% elastane. Lighter. Breathable. Added laser-cut vents behind the thighs. Kept the multi-pocket layout—he wanted seven total, which sounds insane until you realize people carry GPS, knives, protein bars, and bear spray.
MOQ was 300 units. We delivered in 18 days, including sublimated map-pattern lining (his idea). Retailers picked it up fast. Why? Because it worked. Not just looked good.
Pro tip: never glue pockets. Stitch-in-seam only. We found glued pockets delaminating after 30 washes in two factories last year. One in Vietnam, one in Bangladesh. Same supplier. Same mistake.
Gym Shorts (Biker Shorts)
Oh, the biker short. The TikTok darling. The thing every influencer slaps a logo on and calls a “brand.”
Let me tell you something: biker shorts are the most returned activewear item in North America. According to one distributor I know at Nordstrom, return rate averages 19%—mostly for “too tight,” “rolls down,” or “see-through.”
Yeah. See-through.
We had a batch last spring—black biker shorts, 82% nylon, 18% spandex. Client wanted “ultra-sheer, sexy fit.” We warned them. Did lightbox testing. Failed. Went anyway.
Guess what? Photos surfaced online. Women doing squats. Full silhouette visible. Brand got roasted. Had to pull the line.
Now we mandate opacity testing on all dark-colored biker shorts. Simple setup: white lightbox, fabric stretched taut. If you can see fingers through it, it fails. Doesn’t matter how “sexy” it looks on the rack.
Also—waistband construction. Most factories use elastic + binding tape. Cheap. Slips. Ours? Internal silicone grip strip. Tiny detail. Huge difference. Keeps the waistband from sliding during burpees or mountain climbers.
One client in Toronto saw repeat orders jump from 31% to 68% after switching to our grip-band design. Not magic. Just attention.
Swim Shorts
Dry time. That’s the metric. Not style. Not print. Dry time.
We once timed five different swim shorts on a clothesline in Guangzhou humidity: 38%, 44%, 52%, 61%, and one at 78% dry after 45 minutes. The 78%? 100% recycled polyester, 75 denier, brushed interior. The worst? A “premium” cotton-poly blend from a European supplier. Took over two hours.
Cotton has no place in swimwear. None.
But here’s the hidden trap: lining. Some factories skip it to save $.50 per unit. Bad call. Without mesh liner, swim shorts cling. Uncomfortable. Looks amateur.
We use quick-dry mesh with anti-microbial treatment. Costs more. Sells better.
Also—drawstring. Always metal aglets. Plastic melts in the dryer. Seen it happen. Dozens of pairs ruined in one load.
Tennis Shorts
Tennis players are picky. They want freedom of movement, but also a clean, tailored look. No bagging. No riding up.
We do a lot of tennis shorts with split-side hems. Allows stride extension without sacrificing structure. Key is the gusset—diamond-shaped crotch panel. Reduces stress points. Prevents seam blowouts during serves.
One client insisted on flat-front, no pleats. Fine. But when we tested range of motion, hip flexion was restricted by 12 degrees compared to pleated versions. He didn’t believe us until we filmed it.
Lesson: function over form. Even in “style” categories.
Golf Shorts
Golf is slow. Shorts should be too. Meaning: durable, wrinkle-resistant, quiet.
No one wants their shorts crunching like plastic wrap when they address the ball.
We use Tencel-blend fabrics here—soft, drapey, naturally wrinkle-resistant. OEKO-TEX certified, because golfers tend to be older, wealthier, and more sensitive to chemical residues.
One club pro line we made had a recall because the dye wasn’t colorfast. Stained white golf shoes after one round in light rain. Client lost two contracts.
Now we run AATCC Test Method 61 (colorfastness to washing) on every batch. Non-negotiable.
Compression Shorts
These aren’t apparel. They’re medical devices pretending to be clothing.
If you’re making compression shorts, you better understand mmHg ratings—the pressure level applied to muscles. Most factories don’t. They just knit tighter fabric and call it “compression.”
Real compression requires graduated pressure: tighter at the ankle, looser at the thigh. For shorts, it’s usually 15–20 mmHg at the quad, tapering to 8–10 at the hip.
We had a client try to pass off 8% spandex as “medical-grade.” Nope. Actual medical compression shorts use specialized circular knitting machines, not standard jersey loops.
Also—seam placement. Side seams rub. Internal flat seams only. Or better yet, seamless knitting.
One athlete sued a brand last year for nerve irritation from poorly placed seams. Don’t be that brand.
Basketball Shorts
Long. Loose. Flowy.
But not too loose. If they flap in the wind during a fast break, they’ll catch air like a parachute.
We use 30D–50D polyester mesh—light enough to float, strong enough to survive dunk practice. Hem length is critical. Too short? Distracting. Too long? Tripping hazard.
One team order we did for a college in Ohio had a hem that was 1.2 inches longer on the left leg. Factory error. Caught it in pre-shipment. Fixed it. Saved the season opener.
Stitch density? Minimum 12 SPI (stitches per inch). Less than that, and the pocket bar-tacks fail under stress.
Casual Shorts
Alright. Now we’re in the land of “looks good, feels okay.” Most of these don’t need deep technical breakdowns. But I’ll hit the ones that actually move units.
Board Shorts
Surfers don’t care about certifications. They care about dry time and pocket zippers.
We use #8 YKK water-resistant zippers. Not #5. Not generic. #8. Big enough to fit a phone, strong enough to survive saltwater corrosion.
Lining? Quick-dry mesh again. Never bonded film. Peels off after six washes.
Prints matter. Sublimation only. Screen print cracks. DTG fades. Sublimation? Lasts the life of the fabric.
One brand in California pushed back on sublimation cost. Went with screen. Six months later, their Instagram flooded with complaints: “print cracked after first rinse.”
We told them. Politely.
Cargo Shorts
Pockets. Again. But this time, it’s about weight distribution.
Too many pockets? Front-heavy. Sags. Looks sloppy.
We limit to four functional pockets—two front, two rear. No thigh pockets unless requested. And even then, we reinforce the attachment points with bartacks.
Fabric? 200 GSM cotton-poly blend. Durable but not stiff. Pre-shrunk. Always.
One batch we inspected in Shenzhen had pockets sewn with 80/2 thread instead of 120/2. Thread snapped under load test. We rejected it. Factory blamed “operator fatigue.” Doesn’t matter. Garbage in, garbage out.
Chino Shorts
These are tricky. They sit between casual and semi-formal. So the fabric has to look crisp but feel soft.
We use 98/2 cotton-spandex with a light resin finish. Gives that polished drape without sacrificing stretch.
But resin finishes can yellow over time. Especially in heat.
We had a shipment sitting in a container in Long Beach for three weeks during a port strike. Temp hit 118°F. When opened, half the chinos had yellowed fronts.
Now we specify UV-stable resins. And avoid red labels on white garments—bleeds under heat.
Denim Shorts
Raw denim. Washed denim. Distressed. Bleached. Every variation under the sun.
But here’s the truth: most denim shorts are made from leftover jeans.
Factories cut down unsold jeans into shorts. Saves waste. Lowers cost.
We do it too. Called “reclaimed deadstock.” It’s sustainable, yes, but quality varies. One pair might be 12oz selvedge, another 8oz stretch denim.
So we sort by weight and composition before cutting. Otherwise, you get mismatched batches.
One influencer brand didn’t sort. Posted photos of “limited edition” shorts. Fans noticed differences. Accused them of lying about materials. Reputation took a hit.
Always trace your denim source.
Bermuda Shorts
Longer cut. Conservative. Popular in Europe and prep schools.
Waistband must accommodate belts. So we use standard belt-loop spacing—1.5 inches apart, minimum six loops.
Fabric thickness? 220–240 GSM. Any thinner, they look cheap. Any thicker, they cook the wearer.
We had a UK school uniform order where the shorts were 260 GSM. Complaints poured in: “kids overheating.” Switched to 230 GSM with moisture-wicking liner. Problem solved.
Tailored Shorts
These are the hardest.
Why? Because people expect suit-level construction in a garment that goes through sweat, sun, and washing machines.
We use fused interlinings—but only high-quality ones. Cheap fusibles bubble after three washes.
One factory used low-temp adhesive to save energy. Bubbles appeared in 40% of the batch. Had to scrap.
Also—hemming. Double-fold only. No blind stitch. Needs weight to hang right.
Baggy Shorts
Comfort is king. But baggy doesn’t mean shapeless.
We build in subtle taper from hip to hem. Keeps them from looking like sacks.
And always pre-wash. Otherwise, they shrink unevenly and twist on the body.
One batch shrank 5% horizontally but 8% vertically. Result? Twisted legs. Looked drunk.
Swim Trunk Shorts
Same as swim shorts. See above. Only difference? These are marketed for poolside, not swimming.
So more emphasis on print, less on performance.
But still—quick dry. Always.
Hot Shorts
Short. Tight. Bold.
Danger zone: opacity and ride-up.
We use power-knit fabric with higher denier in the seat area. Prevents sheerness.
And internal grip tape on the leg openings. Like biker shorts.
One client skipped the grip. Got 22% returns: “kept riding up.”
Not worth it.
Boxer Shorts
Lounge wear. Not sportswear.
But people wear them for yoga now. So we treat them like performance base layers.
Moisture-wicking. Anti-odor. Flat seams.
And never use printed elastic. Fades. Use jacquard.
Pleated Shorts
Front pleats add volume. Great for style. Terrible for storage.
They crush easily in luggage.
We recommend box-pleats, not knife pleats. Hold shape better.
And starch treatment for retail display. But warn customers: dry clean only.
Boyfriend Shorts
Basically oversized denim cutoffs.
But we cut them from stretch denim now. More comfortable.
And sand the edges lightly. Gives that worn-in look without actual wear.
Raw Edge Shorts
Cut. Don’t hem. Let the edge fray.
But uncontrolled fraying? Looks messy.
We use lock-stitch on the edge with contrasting thread. Controls the fray. Adds style.
Jamaican Shorts
Colorful. Loose. Cultural significance.
But colors bleed. Always test dye fastness.
One festival brand had shorts turn attendees’ legs orange. Settled out of court.
Use reactive dyes. Not pigment dyes.
Slip Shorts
Worn under dresses. Need to be smooth. Silent.
We use microfiber with anti-static treatment.
And seamless sides. No lines under thin fabric.
Skort
Skirt on outside, shorts underneath.
Key: inner shorts must match outer length. Otherwise, it looks broken.
And gusset in the crotch. Non-negotiable for mobility.
One batch had no gusset. Woman bent over. Split up the back. Viral video.
Never again.
Pajama Shorts
Softness > everything.
We use 100% organic cotton or Tencel blend. Brushed finish.
And covered elastic. No digging.
OEKO-TEX Standard 100 is mandatory. Skin sensitivity.
Look, I could go on. But my phone’s blowing up—someone’s having a crisis with a dye lot in Hangzhou.
Just remember: shorts seem simple. But simplicity is the hardest thing to get right.
If you’re starting out, go to Fexwear’s catalog and see what moves. Not what looks good on a mood board. What actually ships, sells, and doesn’t come back.
Need help sourcing fabric? Start here .
Got a sketch on a napkin? Send it to [email protected] —we’ll make it real.
And if you’re tired of getting burned by factories that promise the moon and deliver landfill fodder, come work with people who’ve seen it all, fixed it all, and still show up every damn day.
FAQs
What material is best for moisture-wicking shorts?
80/20 polyester/spandex. Verified in 37 wholesale accounts last year. Anything less than 75% poly loses wicking efficiency.
Which shorts are easiest to customize?
Chino and bermuda. Simple cuts, stable fabrics. We saw a startup go from idea to 500 units in 11 days.
Do I need certifications for casual shorts?
Only if selling to EU or major retailers. But OEKO-TEX costs $200 and prevents lawsuits. Worth it.
Can I mix short types in one order?
Yes. At Fexwear, we do split-batch production all the time. MOQ per style still applies.
How do I prevent color fading?
Use reactive dyes, not pigment. And test with AATCC 61. We caught a bad batch this way last quarter.
Are recycled fabrics durable enough for shorts?
GRS-certified recycled polyester performs within 3% of virgin. We tested side-by-side. Data’s on the site.
Ever had a customer DM you at 2 a.m. asking why their shorts ripped during a downward dog?
Yeah. Me too.
Tell me your war stories. I’m all ears.