Fabric is the most important decision you will make in sportswear design. It determines how the garment feels against the skin, how it performs under physical stress, how it holds its shape after washing, and how long it lasts.
Polyester
Polyester is the workhorse of sportswear manufacturing. It is lightweight, durable, moisture-wicking, and holds its shape exceptionally well. It is also the only fabric that works with sublimation printing.
- Best for: jerseys, training tops, shorts, leggings
- GSM range: 130-200 GSM for performance, 200-280 GSM for heavier applications
- Care: machine washable, quick-drying
- Sustainability: recycled polyester (rPET) options available
Nylon
Nylon is stronger than polyester at the same weight, making it ideal for high-abrasion applications like swimwear, cycling shorts, and compression garments. It has a silkier hand feel than polyester.
- Best for: swimwear, cycling wear, compression garments
- Softer feel than polyester
- More expensive than polyester
- Excellent abrasion resistance
Spandex (Elastane / Lycra)
Spandex is never used alone — it is always blended with other fabrics to add stretch and recovery. A typical performance legging might be 78% polyester and 22% spandex.
- Adds four-way stretch to any fabric
- Provides compression and shape retention
- Standard blend: 78/22 or 85/15 polyester-spandex
- Higher spandex = more compression
Cotton
Cotton is breathable and comfortable but absorbs moisture rather than wicking it away, making it unsuitable for high-intensity performance wear. It is ideal for casual gym wear, hoodies, and lifestyle products.
Fabric Weight Guide
| GSM | Feel | Best Use |
|---|---|---|
| 130-160 | Lightweight | Running tops, jerseys |
| 160-200 | Mid-weight | Training tops, leggings |
| 200-280 | Heavy | Compression wear, shorts |
| 280-320 | Very heavy | Hoodies, sweatshirts |
| 320+ | Premium heavy | Premium hoodies, jackets |
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