What is the typical sample development process for custom activewear?

Start with a detailed design brief, including sketches, reference images, target fabric types, color palettes, sizing charts, and garment features. Clear communication at this stage prevents costly revisions later. ohsurewear works closely with brands to refine concepts for manufacturability.

Choose fabrics that match the desired performance and feel, such as moisture-wicking nylon-spandex blends or sustainable recycled polyester. Suppliers’ certifications and fabric testing are verified to ensure durability, stretch, and opacity.

A pattern is drafted based on design and size specs, followed by a first prototype. This sample allows brands to check fit, elasticity, seam placement, and comfort. Multiple iterations are common to perfect the design.

Samples undergo wear tests, squat tests, and wash/durability assessments. Feedback from designers or test groups informs adjustments to fabric weight, stitching, or garment grading.

Once the sample meets all requirements, a final approved sample serves as the production standard for bulk manufacturing. ohsurewear ensures each approved sample aligns with quality, performance, and branding standards before moving to full production.

A structured sample development process—from concept to pre-production approval—minimizes errors, ensures fit and performance, and sets the standard for consistent, high-quality custom activewear. Partnering with experienced manufacturers like ohsurewear streamlines this process for startups and private label brands.