Fitness Wear Manufacturer for Private Label Gym Brands
Jafsu Enterprises is a cut-and-sew fitness wear manufacturer in Sialkot, Pakistan, making leggings, sports bras, shorts and training tops for gym brands in the UK, USA, Canada, Europe and Australia. Start with one sample piece, then scale from 20 pieces per design and colourway.
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What does a fitness wear manufacturer actually do?
A fitness wear manufacturer turns your design into finished gym clothing: sourcing stretch fabric, cutting patterns, sewing with stretch-safe seams, printing or embroidering your logo, and packing under your label. Jafsu does all of this in one Sialkot factory, from a 1-piece sample to runs of 1,000 pieces or more.
Which fitness garments can a gym brand have made?
We make the core of a gym range, each style cut to your pattern in fabric chosen for how it moves. Pakistan exported $4.966bn of knitwear in FY2025-26, and stretch knits are a large part of that trade.
Leggings and bike shorts
High-rise or fold-over waistbands, gusseted crotch, hidden key pockets and optional scrunch-back seams. See our dedicated leggings in bulk page for waistband and panel options, and our capri leggings page for cropped lengths.
Sports bras
Racerback, cross-back and longline cuts, with removable pads and power-mesh lining where support matters. See our sports bra manufacturing page.
Training tops and tanks
Lightweight, quick-dry tees and racer tanks. Our tank top manufacturing page covers armhole and strap construction.
Gym shorts
Performance-poly shorts with liners, or stretch compression shorts cut from the same knit as your leggings. Combat brands order Muay Thai shorts and MMA shorts from the same floor.
Hoodies and joggers
Warm-up layers in French terry or brushed fleece. For heavier streetwear-style cuts, see our custom hoodie manufacturing page and our joggers and sweatpants range.
What fabric weight should gym wear be?
Tight-fitting gym wear usually sits between 220 and 300 GSM, while loose training tops run lighter, at 140 to 220 GSM. Sportek describes 120 to 170 GSM as common for activewear tops, with 180 to 250 GSM as the versatile middle ground.
| Fabric use | Typical composition | GSM | oz/yd² | Basis |
|---|---|---|---|---|
| Gym and activewear | 75% nylon / 25% spandex, poly-elastane | 220–300 | 6.5–8.8 | Jafsu spec |
| Performance tops and shorts | Interlock, birdseye mesh, micro poly, poly-spandex | 140–220 | 4.1–6.5 | Jafsu spec |
| Leggings, mid-weight | Nylon-spandex 78/22 | 200–250 | 5.9–7.4 | Industry reference |
| Leggings, squat-proof | Nylon-spandex, poly-elastane | 260–320 | 7.7–9.4 | Industry reference |
| Sports bra lining | Poly-spandex power mesh | 120–160 | 3.5–4.7 | Industry reference |
| Tank top, training tee | Poly, poly blends | 130–180 | 3.8–5.3 | Industry reference |
Rows marked industry reference show where the market usually works, not a promise for your style. The weight for your range is fixed on the 1-piece sample. Conversion used: 1 oz/yd² equals 33.9 GSM.
How are leggings and sports bras built to survive squats?
Stretch garments fail at the seams first. We sew leggings with 4-needle flatlock stitching, which lies flat and stretches with the knit. Our cut and sew process covers pattern and grading.
- Gusseted crotch. A diamond panel removes the 4-way seam junction.
- Waistbands. High-rise, fold-over or wide shaping bands, with an optional tummy control panel.
- Scrunch-back seams. A ruched centre-back seam.
- Sports bra support. Removable pads, power-mesh lining and elastic under-bands sized to your spec.
- Coverstitched hems. Flat hems that stretch without rolling.
What is the MOQ, and how does an order go from sample to bulk?
The minimum is 20 pieces per design and colourway, after a 1-piece sample. A new label can test 3 colourways of one legging with 60 pieces.
Mockup and costing
Send a sketch or tech pack; get a mockup and price with breaks at 100, 300, 500 and 1,000+.
1-piece sample
One piece in your fabric, colour and decoration, paid 100% in advance.
Approval and deposit
Once you sign off the sample, a 50% deposit books the bulk run.
Bulk production
Cutting, sewing, decoration and labelling against the approved sample.
QC photos and video
You review photos and video of the finished order, then pay the 50% balance.
Shipping
DHL, FedEx or UPS door to door, or air cargo and sea freight for larger orders.
Which logo methods hold up to sweat and stretch?
On stretch fabric, the best logo method is one that moves with the knit: sublimation or silicone heat transfer. Both are done 100% in-house, alongside screen printing and embroidery.
Sublimation
Ink becomes part of polyester-rich fabric, so all-over prints never crack or peel. See sublimation printing.
Silicone transfer
Raised, soft-touch logos that flex with the waistband or bra band.
Screen print
Plastisol, water-based or high-density ink for bold chest and back marks on tops. See screen printing.
Embroidery
Small, stable marks on hoodies, joggers and heavier knits where stretch is low. See embroidery.
Screen print and embroidery are not ideal on 220–300 GSM four-way stretch leggings, where a rigid mark can crack or pucker. We will recommend sublimation or silicone instead.
How do you control shrinkage and fit before bulk?
Shrinkage is controlled by agreeing a test method and a tolerance in writing before bulk. The reference method is AATCC Test Method 135, which measures change in length and width after home laundering. It sets no maximum, so the limit is agreed between buyer and factory.
Put the tolerance on the order
Name the wash and dry cycle and the accepted percentage for each fabric in your tech pack. Stretch nylon and cotton fleece rarely share 1 number.
Fit locked by the sample
We grade youth YS to YXL and adult S to 4XL. The measurements of the 1 approved sample become the reference every size is checked against.
Many suppliers quote a single “allowed” shrinkage figure as if a standard set it. None does, which is why the number belongs in your contract.
When is a Sialkot fitness wear manufacturer the wrong choice?
If one of these 4 describes you, another route will serve you better.
Untested designs
If you have not sold a single piece yet, print-on-demand lets you test demand with 0 stock.
10,000+ piece programmes
Very large single-style volumes are better priced by big vertical mills.
Stock in under 4 days
A local decorator printing on blanks will beat any cut-and-sew lead time.
Blank basics only
If you only need plain stock garments, a blanks wholesaler is faster and cheaper.
What do gym brands ask before their first order?
The 10 questions we hear most often from brands launching or moving a fitness range.
What is the minimum order for custom fitness wear?
Production starts at 20 pieces per design and colourway, after a 1-piece sample made in 7 to 10 working days. Quotes carry price breaks at 100, 300, 500 and 1,000 or more pieces.
How long does fitness wear production take?
Mockups take 24 to 48 hours and samples 7 to 10 working days. Bulk takes 14 to 18 working days for 50 to 300 pieces and 20 to 25 working days for 500 to 1,000 or more.
Do you make a sample before bulk production?
Yes. Every range starts with a 1-piece sample paid 100% in advance, and the approved sample becomes the reference for fabric, fit, colour and decoration.
What fabric is best for leggings and sports bras?
Four-way stretch knits such as 75% nylon with 25% spandex, or poly-elastane, worked at 220 to 300 GSM. Poly-spandex suits designs that will be sublimation printed.
How can I make leggings squat-proof?
Use a heavier, denser knit, roughly 260 to 320 GSM by industry reference, and stretch-test your 1-piece sample under bright light before approving bulk.
What sizes can you manufacture?
Youth sizes YS to YXL and adult sizes S to 4XL, graded from your size chart or from a base size set on the sample.
Can I add my own labels and packaging?
Yes: woven neck labels, satin wash-care tags, PVC tags, embossed swing tags and branded polybags. Your artwork is never reused or resold.
Which countries do you ship fitness wear to?
The UK, USA, Canada, Europe and Australia. DHL, FedEx and UPS deliver door to door in 4 to 6 business days, with air cargo and sea freight for larger orders.
What payment terms do you use?
Samples are 100% in advance. Bulk is 50% deposit and 50% before dispatch, paid after you review QC photos and video of the finished order.
Do you publish prices for gym wear?
Not as a fixed list, because fabric and decoration drive cost. Send your design and quantities for a costed quote within 24 to 48 hours.
Ready to sample your first fitness style?
Send a sketch, tech pack or reference garment. You will get a mockup and a costed quote within 24 to 48 hours, and a 1-piece sample within 7 to 10 working days of approval.