Custom Sportswear Manufacturer
Sportswear Manufacturers in the USA: Custom, Private Label & Wholesale Solutions
At DesignTo Clothing, we manufacture custom sportswear and activewear built for performance, comfort, and brand identity. Every garment is constructed from technical fabrics through our cut-and-sew production process — not from decorated blanks.
Sportswear is one of the most technically demanding apparel categories. The fabrics need to wick moisture, stretch in multiple directions, resist pilling, and hold their shape through hundreds of washes. The construction needs flatlock seaming, bonded panels, and reinforcement at stress points. And the printing needs to bond permanently with performance fabrics without cracking or restricting movement. We manage all of it.
Our minimum order starts at 30 units per style and color — accessible for fitness startups, gym brands, team sports, corporate wellness programs, and established activewear labels scaling production.
Products We Manufacture
A full range of sportswear and activewear for men, women, and unisex collections. Every product is fully customizable.
Tops
Performance tees, tanks, muscle tees, long-sleeve training tops, compression tops, and crop tops. Fitted, relaxed, or oversized.
Bottoms
Leggings, compression tights, joggers, track pants, training shorts, biker shorts, and running shorts with zip pockets and reflective details.
Outerwear
Windbreakers, lightweight jackets, track jackets, warm-up suits, and zip-up hoodies. Coated or laminated for wind and water resistance.
Sports Bras
Light, medium, and high-impact support. Racerback, cross-back, traditional straps. Adjustable or fixed, removable padding, moisture-wicking fabrics.
Team Uniforms
Custom jerseys, training kits, warm-up sets for sports clubs, leagues, schools, and corporate fitness. Sublimation for full-color team graphics and numbers.
Matching Sets
Coordinated top-and-bottom sets. Matching fabrics, colors, and construction for cohesive activewear brand launches and seasonal collections.
Performance Fabrics
Technical textiles engineered for athletic applications. We source based on your product type and performance requirements.
Polyester Mesh & Interlock
Lightweight, breathable, quick-drying. Excellent moisture-wicking for training tops, jerseys, and shorts.
Ideal for sublimation printing — polyester's dye receptivity produces the most vibrant all-over prints.
Nylon-Spandex
Smooth, durable, and stretchy with excellent recovery. The premium standard for leggings, compression wear, and fitted tops.
Typical blend: 75–80% nylon, 20–25% spandex for four-way stretch
Polyester-Spandex
More affordable than nylon blends with strong moisture management. Good stretch and recovery. Brushed, peached, and smooth finishes available.
Popular for mid-range activewear and high-volume production
Moisture-Wicking / DRI-FIT
Engineered to pull sweat from skin to fabric surface for evaporation. Available in polyester and nylon-based constructions.
Essential for any garment designed for physical activity
Compression Fabrics
High-density stretch fabrics applying graduated pressure. Supports muscle recovery, reduces fatigue, improves circulation during activity.
For compression leggings, shorts, tops, and sleeves
Recycled Performance
Recycled polyester, recycled nylon (ECONYL), and certified sustainable fabrics. Lead with sustainability without sacrificing performance.
GRS and OEKO-TEX certifications available on request
Learn more on our fabric and material processing page.
Construction Features
Every detail engineered for movement, durability, and comfort during physical activity.
Printing and Decoration
Multiple decoration methods depending on fabric, design, and coverage area.
The dominant method for sportswear. Full-color, edge-to-edge prints with zero hand feel. Ink bonds into polyester fibers and stretches with the fabric. Ideal for jerseys, leggings, and all-over training tops. Only works on white/light polyester.
Logos, team names, bold graphics on cotton-blend or dark sportswear. Cost-effective for simple designs at volume.
Small logos on chest, sleeve, or collar. Premium textured detail. Popular on jackets, warm-ups, and track tops.
Names, numbers, and single-color logos. Common for team jerseys where individual customization is needed per garment.
Reflective ink or film for visibility during low-light conditions. Functional for outdoor running and cycling apparel.
Branding and Private Labeling
Every garment fully branded as your own through our private label services.
Woven or printed at neckline or side seam with your brand name.
Inside neck or waistband with your sizing system.
FTC-compliant for your performance fabric. Details here.
Printed directly onto garment interior. No sewn tag irritation during activity. Premium standard.
Custom cards with brand story, pricing, or barcodes.
Poly bags, tissue, or branded mailers. Learn more.
Our Sportswear Manufacturing Process
Every order follows a structured workflow from concept to finished product.
Design & Specifications
Send your design — sketches, photos, tech pack, or description. We confirm garment type, fabric, construction, fit, print method, and branding.
Fabric Sourcing
Performance fabrics sourced to your specs — fiber, stretch, weight, moisture management, and certifications. Swatches for approval. Learn more.
Sampling
Physical prototype with your actual fabric, construction, and branding. Starts at $250 delivered. Review fit, fabric performance, and appearance before bulk.
Printing
For sublimation, fabric printed flat before cutting. For screen printing or embroidery, applied after construction. Sublimation details.
Cutting & Sewing
Fabric cut to pattern, assembled through cut and sew production. Flatlock or bonded seaming. Ventilation, pockets, waistbands installed per specs.
QC & Packaging
Every garment inspected for seaming, print alignment, stretch recovery, fabric consistency, and sizing. Labeled, tagged, packed, shipped. Quality standards.
Markets and Applications
Custom sportswear serves a wide range of markets. We work with clients across all of these categories.
Why Brands Choose DesignTo Clothing for Sportswear Manufacturing
Complete sportswear production — from performance fabric sourcing through construction, printing, branding, and packaging under one pipeline.