COMPLETE FABRIC GUIDE

Activewear Fabrics
Explained

The definitive guide to choosing the right sportswear fabric for your brand. Polyester, cotton, spandex, blends — and which one fits your product, your market, and your performance needs.

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Min GSM
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Brands Served
OEKO-TEX 100Certified Safe
ISO 9001:2015Quality System
GOTS CertifiedOrganic Options
In-House LabQuality Testing
DHL / FedExExpress Delivery
OVERVIEW

What Are Activewear Fabrics?

Activewear fabrics are engineered textiles designed specifically for physical activity — built to manage moisture, regulate temperature, stretch with movement, and endure repeated washing and intense use.

"The right fabric can make or break an activewear brand. A running tee that stays wet, a yoga legging that loses shape, or a hoodie that pills after three washes — these are brand-killers that start with the wrong fabric choice."

Unlike fashion fabrics, activewear textiles are selected based on performance metrics: moisture-wicking rate, dry time, stretch recovery, abrasion resistance, and pilling grade. The choice between polyester, cotton, spandex, or a blend isn't arbitrary — each serves a specific function.

At Dhalay International, we manufacture 7 distinct activewear fabric types in our Sialkot facility, each available in multiple GSM weights, compositions, and finishes. This guide helps you select the right one for your product line.

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Fabric Types
Collection of activewear fabric swatches
Performance Engineered
OUR FABRIC RANGE

7 Activewear Fabric Types

Each fabric type serves a distinct purpose. Click through to explore specifications, GSM options, and pricing for each.

Polyester Fabric

The workhorse of performance sportswear. Lightweight, moisture-wicking, sublimation-ready, and extremely durable.

100–280 GSMSublimationMost Popular

Cotton Fabric

Natural softness and breathability for casual sportswear, training basics, and lifestyle activewear.

140–350 GSMScreen / DTGOrganic Option

Spandex / Elastane

High-stretch fibers for compression wear, yoga pants, swimwear, and form-fitting performance gear.

180–280 GSM4-Way StretchCompression

French Terry

Loop-back construction for premium hoodies, joggers, sweatshirts, and athleisure essentials.

240–380 GSMLoop-BackAthleisure

Bamboo Fabric

Eco-friendly, ultra-soft natural fiber with natural antimicrobial properties for wellness and yoga wear.

160–280 GSMAntimicrobialSustainable

Interlock Fabric

Double-knit construction with smooth faces on both sides — ideal for premium polos and fitted tops.

160–260 GSMDouble-KnitNo Curling

Mesh Fabric

Open-structure knit for maximum airflow — used in basketball jerseys, panel inserts, and ventilation zones.

80–160 GSMMax AirflowPanel Inserts
COMPARISON

Fabric Performance Compared

How do the key fabrics stack up against each other on the metrics that matter most?

Fabric Moisture Wicking Breathability Stretch Durability Softness Best For
Polyester
95%
80%
40%
95%
55%
 Team uniforms, running, training
Cotton
25%
90%
15%
60%
95%
 Lifestyle, casual, training basics
Spandex Blend
70%
65%
98%
80%
75%
 Compression, yoga, swimwear
French Terry
30%
70%
30%
85%
88%
 Hoodies, joggers, athleisure
Bamboo
55%
85%
35%
55%
92%
 Wellness, yoga, eco-friendly lines
Interlock
45%
75%
25%
80%
82%
 Premium polos, fitted tops
DECISION GUIDE

Which Fabric Should You Choose?

Match your product type to the right fabric — based on what matters most for that specific garment.

Running & Training Tees

Need lightweight, fast-drying fabric that moves sweat away from the body instantly. Sublimation-ready for all-over prints.

100% Polyester — 130–160 GSM

Team Uniforms

Must handle sublimation for custom team designs, withstand aggressive play, and maintain color after 50+ washes.

Polyester or Poly-Spandex 88/12

Yoga & Compression

Requires 4-way stretch, shape retention after hundreds of stretches, and a soft, second-skin feel against the body.

Poly-Spandex 82/18 — 200–240 GSM

Hoodies & Joggers

Need warmth, structure, and a premium hand feel. The fabric should hold its shape and resist pilling over time.

French Terry or Cotton 300–360 GSM

Premium Polos

Structured yet comfortable. Must resist curling at edges, hold embroidery well, and look crisp wash after wash.

Interlock Poly-Cotton 65/35

Eco-Friendly Lines

For sustainability-focused brands. Natural, biodegradable, with a premium softness that communicates conscious luxury.

Bamboo or GOTS Organic Cotton
BLENDS

Most Popular Blends & Why

Pure fabrics have strengths and weaknesses. Blends combine the best of both — here are the combinations our clients order most.

88/12 Poly/Spandex
Most Ordered
Performance Stretch
The gold standard for performance jerseys, athletic shorts, and fitted training tops. Polyester handles moisture-wicking while 12% spandex provides comfortable 4-way stretch without losing shape.
Jerseys Athletic Shorts Training Tops Baseball Tees
82/18 Poly/Spandex
High-Stretch Performance
Extra spandex content for garments that need to stretch and recover repeatedly — leggings, compression shorts, and form-fitting activewear where second-skin feel is non-negotiable.
Leggings Compression Shorts Rash Guards Cycling Kits
65/35 Cotton/Poly
Best Value
Comfort-Durable Blend
The sweet spot between cotton's natural feel and polyester's durability. Resists wrinkling, shrinks less than pure cotton, and takes both screen printing and embroidery beautifully.
Polos Promotional Tees School Wear Corporate Sport
60/40 Cotton/Poly
Soft-Structured Blend
More cotton content means a softer hand feel while still gaining poly's dimensional stability. Popular for premium casual sportswear where comfort is the top priority.
Casual Tees Lifestyle Wear Warm-Ups
95/5 Cotton/Spandex
Natural Stretch
Keeps cotton's natural look and feel while adding just enough stretch for comfort and movement recovery. Ideal for brands that want "natural" positioning with performance comfort.
Fitted Tees Polo Shirts Casual Shorts
80/20 Cotton/Poly
French Terry Blend
The classic hoodie and jogger composition. High cotton content for softness and warmth, with enough polyester for structure, reduced shrinkage, and pilling resistance in heavy loop-back fabrics.
Hoodies Joggers Sweatshirts Warm-Up Suits
GSM GUIDE

GSM Range for Every Garment

GSM (grams per square meter) determines weight, drape, and warmth. Here's what to spec for each garment type.

100–130
GSM

Mesh & Liners

Basketball jerseys, mesh panel inserts, garment liners

130–160
GSM

Lightweight Tees

Running tops, summer training, sublimation jerseys

160–200
GSM

Standard Training

Gym tees, casual polos, everyday activewear

200–240
GSM

Premium & Compression

Premium polos, compression tops, leggings, shorts

240–300
GSM

Heavyweight & Terry

French terry hoodies, track pants, warm-up gear

300–400
GSM

Heavy Fleece & Outerwear

Heavy hoodies, fleece jackets, cold-weather gear

APPLICATIONS

Garments We Produce

From lightweight mesh jerseys to heavy fleece outerwear — our fabric range covers the full activewear spectrum.

Running Tees
Team Jerseys
Training Tops
Polo Shirts
Compression
Yoga Wear
Hoodies
Joggers
Sweatshirts
Shorts
Swimwear
Mesh Panels
Athleisure
Warm-Ups
Outerwear
Sports Polos
Corporate Sport
School Sport
PRINTING METHODS

Four Printing Technologies

Different fabrics demand different printing methods. Here's what works with what — and why.

Sublimation printing on polyester fabric
Polyester Only

Sublimation

Heat-transfer process that bonds dye directly into polyester fibers. All-over, full-color, photo-quality designs with zero hand feel. The gold standard for team jerseys and performance wear.

All-Over PrintZero Hand FeelPolyester OnlyNo Fading
Screen printing on sportswear
All Fabrics

Screen Printing

Ink pushed through mesh stencils onto fabric. Bold, opaque colors that last hundreds of washes. Works on all fabric types. Best value for bulk orders with simple designs.

1–12 ColorsBold & OpaqueAll FabricsBulk Pricing
DTG printing on cotton activewear
Cotton & Blends

Direct-to-Garment

Digital inkjet printing directly onto fabric. Photo-quality, unlimited colors, no setup cost. Best for cotton and cotton-rich blends. Ideal for small batches and complex art.

Full-ColorPhoto QualityNo SetupLow MOQ
Embroidery on activewear polo
All Fabrics

Embroidery

Thread stitched directly into fabric for a textured, premium look. Communicates quality and craftsmanship. Perfect for polo logos, chest branding, and monograms on any fabric.

TexturedPremium LookAll FabricsPermanent
CUSTOMIZATION

Full Custom Capabilities

Every aspect of your activewear fabric can be engineered to your exact brand specifications.

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Fabric Selection

Choose base fabric, composition ratio, and construction type from our 7 fabric families.

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Custom GSM

Specify exact weight between 80–400 GSM, tailored to your garment's performance needs.

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Color Matching

Any Pantone TPX/TCX matched with ΔE < 1.0. Reactive dye for cotton, disperse dye for polyester.

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Finish Treatments

Anti-microbial, UV protection, moisture-wicking finish, anti-pilling, bio-polish, enzyme wash.

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Print & Branding

Sublimation, screen print, DTG, or embroidery. Woven labels, hang tags, neck labels included.

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Packaging

Individual poly bags, custom printed boxes, retail-ready packaging, or bulk bale shipping.

HOW IT WORKS

Ordering Process

From first contact to delivery — a streamlined 5-step process for any fabric type.

Inquiry

Day 0

Samples

3–5 Days

Approval

1–2 Days

Production

15–21 Days

Delivery

4–7 Days
Total turnaround: 23–35 days from inquiry to doorstep. Rush orders available in 15–20 days.
ORDER DETAILS

Capacity & Lead Times

500 pcs
Minimum Order Quantity
Fabric-only: 200 meters
50K pcs/mo
Combined Capacity
Across all fabric types
15–21 days
Production Lead Time
Rush: 10–12 days
Free
Fabric Swatch Samples
Shipped within 48 hours
FAQ

Frequently Asked Questions

There is no single "best" fabric — it depends on the activity. Polyester blends dominate high-performance sportswear for moisture-wicking and durability. Cotton is ideal for casual and lifestyle activewear. Spandex blends are essential for compression and form-fitting garments. Most premium brands use carefully engineered blends that combine the strengths of multiple fibers for a specific end use.
Major brands primarily use polyester-based fabrics — often 100% polyester or polyester-spandex blends (88/12, 82/18). Nike uses Dri-FIT (polyester microfiber), Adidas uses Climalite and Aeroready (polyester blends). These fabrics offer moisture-wicking, lightweight feel, and are ideal for sublimation printing. For lifestyle lines, they use cotton-polyester blends.
For high-intensity gym workouts, polyester is clearly superior — it wicks moisture, dries fast, and maintains its shape. Cotton absorbs sweat and stays wet, which can feel heavy and cold. For light gym sessions, warm-ups, or lifestyle gym wear, cotton blends (60/40 or 65/35) offer a comfortable compromise with better looks and a natural hand feel.
Lightweight performance tees: 130–160 GSM. Standard training tops: 160–200 GSM. Premium polo shirts: 200–240 GSM. Hoodies and sweatshirts: 280–350 GSM. Compression gear: 180–220 GSM with high spandex content. The right GSM depends on the garment type, season, and intended use — we can help you spec the perfect weight.
Yes — we frequently produce multi-fabric orders. For example, a brand might order polyester jerseys for team uniforms, cotton hoodies for sideline gear, and spandex shorts for training — all in one production run with coordinated colors and branding. This is especially common for sports clubs and athletic brands with full product lines.
Our standard MOQ is 500 pieces per fabric type and color. For fabric-only orders (no cut-and-sew), the minimum is 200 meters. We offer lower MOQs for sample and development orders — contact us with your specific requirements and we'll do our best to accommodate. First-time clients often start with a sample order of 50–100 pieces.
It depends on your fabric and design. Sublimation is best for polyester — all-over prints, unlimited colors, zero texture. Screen printing works on all fabrics for bold, simple designs in bulk. DTG is ideal for cotton and small batches with complex art. Embroidery adds premium texture for logos on any fabric. If you're unsure, send us your design and we'll recommend the best method.
Yes — we provide free fabric swatch samples shipped within 48 hours. For serious buyers, we also offer paid sample garments (typically $30–80 per style depending on complexity) that are credited against your bulk order. This lets you test the actual fabric, print quality, and construction before committing to production.

Not Sure Which Fabric to Choose?

Tell us your product type, target market, and performance needs — we'll recommend the perfect fabric and send free swatches within 48 hours.

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