Custom Yoga Wear Manufacturer

Yoga leggings and set styles: developing a programme from a reference pair

This archive carries two reference leggings, both high-waisted and lightweight, so treat the page as a starting point rather than a range to shop. Pick the closer card, mark what stays and what changes, and the pattern is built from there. Cut-and-sew yoga leggings start at 100 pieces per style per colour, with sizes mixed inside one colourway; bonded or seam-sealed work starts at 200. Samples take 3–7 days and bulk production 15–25 days after sample approval.

Read the two reference leggings, then mark your changes

Both cards are high-waisted lightweight leggings written for Pilates, running, fitness and gym sessions, one described as non see-through and the other as stretchy. Neither is stock. The card gives a body, a rise and a look, while fabric, colour, size range, labels and packing come from your brief. Keep the link, then list the parts you are keeping: band height, leg length, panel lines, seam placement and the position of any logo.

A reference also sets a limit. If the programme needs a flare leg, a capri, a wide leg, a sculpting double knit or a bonded waistband, say so in the first message so the change is quoted against the card. A different pattern is a different style for the minimum: two leggings on different blocks count as two styles, each with its own 100 pieces per colour.

Settle rise, leg length and waistband before the fabric conversation

Rise, leg length and band decide whether the finished legging feels like the reference. We confirm waist, hip, rise and inseam on the first sample and grade from those numbers, on any size set you specify: plus, petite, tall, maternity and kids included, on US, EU or Asian grading.

Full length, 7/8, capri, flare and wide leg all come off our lines, and each changes the marker and the fabric consumption, so the choice belongs in the quotation. High-rise bands are built with or without a hidden waistband pocket, and a gusset is part of every full-length style. State the band height, how it is attached and the tension you want at the top of the size range.

Extended sizes are graded from the standard block rather than scaled up, with band tension and rise adjusted size by size so the fit holds at the end of the range.

Pick the knit by weight and blend together, never one without the other

Three blends cover the yoga programmes we run. Nylon-spandex gives the softest hand feel and the best opacity for its weight, at 220–260 GSM for full-length leggings. Polyester-spandex dries faster, costs less and takes sublimation, and needs more weight, around 230–240 GSM, for comparable coverage. Recycled polyester-spandex carries the same performance with recycled-content documentation arranged to the order. Sculpting leggings run 260–300 GSM on a high-density double knit.

Weight and blend are quoted as a pair, because 220 GSM nylon and 220 GSM polyester do not behave the same way. Swatch cards with composition and GSM written on each go out with the quotation. Where you already work with a mill, fabric can be bought from the supplier you nominate.

Knit structure is named on the spec sheet too: interlock and high-density double knit hold coverage under tension where an open jersey does not.

Check opacity on the lightest colourway, not on black

Squat-proof is the result of six decisions agreeing: weight and blend taken together, knit structure, spandex content and recovery, yarn coverage, colour, and pattern fit. A fabric that passes in black can go sheer in pale grey, so the lightest colourway in the range is tested first and every colourway is tested separately, with the fabric held at working extension over a contrasting board and photographed.

Pattern belongs on that list. If the back rise is cut too tight, good fabric is pulled past its working range and the seat thins under load, so fabric and pattern are signed off together rather than one after the other. Recovery is read at 30, 50 and 80 percent extension across warp, weft and bias, and the readings travel with the sample instead of waiting to be requested.

Where your market asks for OEKO-TEX Standard 100, GRS scope certificates or REACH documentation, panels can go to a laboratory you nominate, within China, and the report is passed on as it comes back.

Build the set: legging and top from one dye lot

Matched sets are where colour consistency across two garments matters most, and both pieces are cut from the same lot where the programme allows. A set is two styles for the minimum: 100 pieces of the legging and 100 of the top in the ordered colour. Tops for the upper half sit in the tank top archive, so a set brief normally names one reference from each page.

Colour is approved on lab dips before bulk fabric is bought, and dips run alongside pattern making. Deep blacks and dark navy get fastness checks to washing and perspiration before release.

Edges, decoration and the checks before packing

Flatlock and coverstitch seams are tested for elongation and recovery so the seam stretches with the fabric instead of popping, and that is what we specify on leggings. Laser cutting runs mainly on synthetics and seals the edge as it cuts, which suits clean leg and armhole openings. Bonded edges close without a stitch line, at 200 pieces per style per colour.

Decoration follows the fabric. Sublimation covers all-over print on polyester-rich cloth before cutting, screen print uses an elastic ink that stretches with the knit, heat transfer and silicone give flat low-profile marks, and embroidery is backed so the stitch area stays soft against skin. Sampling is charged, and the fee is offset against the invoice when a first order reaches 300 pieces of a style.

Incoming fabric is weighed on a circular cutter gsm scale and checked against the approved weight, colour and surface. Checks run through cutting, in-line construction, finishing and measurements, with needle detection on the packing line. Cartons are sampled to AQL 2.5 under ISO 9001, against an approved order file and a sealed pre-production sample.

Send the card link or a tech pack with the quantity per colour, the size range, the fabric and the construction points that must change. For a set, send both references in one message so they are costed as one programme. The reply is a quotation built on that specification, with fabric swatches, a sampling date and a bulk window rather than a shelf price.

Frequently asked questions