Made in USA production
Made in the USA · Activewear & leggingsLeggings, sports bras, bike shorts and performance tops from US factories that sew stretch fabric every day, from 100 pieces per style. Send a brief and we place it with a line built for your fabric, seams and fit.
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Spec tag · Activewear
Activewear needs a line with the right machines for stretch fabric (coverstitch, flatlock) and a fabric supplier that stocks performance knits. Two hubs cover that.
Product, fabric, quantity and timing decide the factory first; the hub follows from that. You get the factory’s name and direct contact, and you can visit before you sign off a sample.
Activewear is one of Los Angeles’ core strengths, next to cut and sew and knits. The first place we look for leggings, sports bras and performance sets.
Hub strengths Cut & sew, denim and washes, knits, activewear
Los Angeles hubActivewear knits are a Carolinas strength. A strong option when you want the fabric knitted in the US too, which decides the label.
Hub strengths Knit fabric mills, fleece, tees, socks, activewear knits
The Carolinas hubSampling and patternmaking. Useful for developing a new fit before bulk; we rarely place an activewear production run here.
Hub strengths Sampling, patternmaking, womenswear, wovens and dresses, small runs
New York Garment District hubFrom a core legging to a full studio set: pick the style, the performance fabric and the seams, and we place it with a factory that already sews stretch.
Leggings
Full length, 7/8 and capri; high rise, pockets, with or without side seams.
Sports bras
Pullover, racerback or adjustable; removable cups.
Bike and running shorts
Inseam lengths from short to long; liners and pockets.
Performance tops
Tanks, fitted tees and long sleeves in technical knit.
Unitards and bodysuits
One-piece studio and dance styles.
Track and warm-up
Joggers, half-zips and jackets for the set.
Nylon-spandex
Smooth, compressive knits for leggings and bras.
Polyester-spandex
Moisture-wicking knits, often recycled polyester.
Brushed and peached knits
Softer, matte hand for studio wear.
Mesh
Ventilation panels and linings.
Weight and stretch
Name the weight in gsm and the stretch you need (compression or relaxed).
US-knit or imported
Both work. The choice decides the label wording (see below).
Waistband elastic
Covered or exposed elastic, drawcords.
Bra cups and underband
Removable cups, elastic underband, adjustable straps and hooks.
Zippers and pockets
Hidden key pockets, zip pockets, phone pockets.
Labels
Heat-transfer labels for a tagless feel, care and content labels.
Heat transfer
Logos and marks that stretch with the fabric.
Sublimation
All-over prints on polyester knits.
Reflective details
Reflective prints or tapes for running styles.
Embroidery
Small marks on heavier knits only; ask first.
Flatlock and coverstitch seams
Flat seams that don’t chafe.
Bonded and laser-cut edges
Clean, hem-free edges, where the factory offers it.
Gusset
A diamond or triangle crotch gusset for leggings and shorts.
Fold, bag and label
Folded, polybagged and size-labelled, ready for your warehouse.
Stretch fabric needs specific machines, so we only place activewear with factories that already sew it; the quote lists which seams they run.
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US-made activewear costs more at the factory than imported, with no ocean freight, customs or import duty on top. Here is what the calculator estimates today, before prints.
Calculator estimate, full package, ex-factory; your quote may differ.
$19.20–$50.40
USD per piece, activewear
Quantity multiplier ×1.20
$16.00–$42.00
USD per piece, activewear
Quantity multiplier ×1.00
$14.08–$36.96
USD per piece, activewear
Quantity multiplier ×0.88
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What “full package” means
The factory buys the fabric, cuts, sews and adds standard trims, and quotes one price per piece at its door. Decoration, premium fabric, a complex build and shipping move the number; the cost calculator shows by how much. Bonded seams, bra cups, multiple panels and specialty fabrics move you toward the top of each range.
Made in the USA, step by step
The steps your order goes through at a US factory. Photos show the production steps, not a specific factory.
01 · KnittingStretch knits from US mills
02 · CuttingCut on the cutting tables
03 · SeamsCoverstitch and flat seams
04 · DecorationEmbroidery and printing nearby
05 · Label“Made in USA” woven label
06 · PackingBoxed for ground shipping
Free brief · Reply within 24h · The factory bills you directly.
These timings apply to every product we place. For activewear, performance fabric is the usual swing factor: stock colors from the mill keep you at the short end.
Day 1
Product, quantity, fabric, target cost and date. We reply within 24 hours and quote our fee in writing before any work starts.
3–5 working days
Optional. $79 per style with 2–3 revision rounds. Skip it if your tech pack is ready.
2–4 weeks
A fit sample in your performance fabric. Approve fit, compression, squat-test opacity and seams before bulk.
4–6 weeks
Cutting, sewing, printing and finishing after sample sign-off. We check the label wording before the first bulk run.
1–5 days
Straight from the factory to your door or warehouse in the lower 48. No port, no customs broker, no import duty.
First order: 8–12 weeks from brief to delivery.
Repeat orders skip sampling. Fabric availability is the usual swing factor, so name your fabric early.
“Made in USA” is a legal claim. For textiles the FTC looks one step back from the finished product, so the wording depends on where the performance fabric was knitted and where the piece was cut and sewn.
Performance knits: the knitting mill decides the wording
Ask where your nylon-spandex or polyester knit was knitted early in the brief. A legging sewn in the US from a knit made abroad needs the imported-fabric wording, on the label and on the product page.
MADE IN USA
78% nylon · 22% spandex
Performance knit made by a US mill, then cut and sewn by a US factory. This is the plain “Made in USA” label.
Common mistakeUsing this label on leggings sewn here from fabric knitted overseas. The sewing is local, the fabric is not.
MADE IN USA
OF IMPORTED FABRIC
88% polyester · 12% spandex
Cut and sewn here from a performance knit made abroad. You may name the country instead of “imported”.
Common mistakePrinting plain “Made in USA” on a heat-transfer label because the sewing is local. The qualifier is required.
Plain-English summary, not legal advice. Source rules: the FTC’s textile labeling guide and Made in USA standard.
Stretch garments are fit-critical, so detail pays. A photo of a style you like plus the list below is enough to start.
Example tech pack: a flat for a zip-front track jacket, by Pinterest user Di Dii
We draw it for $79 per style.
Flats, measurements, construction and trims in the format US factories quote from. 3–5 working days, 2–3 revision rounds. How the tech pack service works.
Get your tech pack for $79One flat fee per style. Secure Stripe checkout.
Brief checklist · Activewear
Tick what you have. Gaps are fine: we ask about them when we reply.
Sending a brief is free. Our fee is quoted in writing before any work starts, never tied to order size, and the factory bills you directly.
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Minimums, cost, fabric, seams and labels for US-made leggings, bras and performance wear.
Question not covered here?
Email it with your product and quantity. We reply within 24 hours.
oneaimapparel@gmail.com100 pieces per style, the same as every other product we place. Put the size split and colors in the brief and we only place you with factories that take that quantity.
The cost calculator currently estimates $19.20–$50.40 per piece at 100–300 units and $16.00–$42.00 at 300–500 units, full package, ex-factory, mid fabric and standard complexity, before prints. It’s an estimate: your quote depends on the factory, fabric, style and tech pack.
Yes, if the performance fabric was knitted in the US and the piece was cut and sewn here. If the fabric was knitted abroad, the label must say “Made in USA of imported fabric” (or name the country). We check the label and listing wording before the first bulk run.
We only place activewear with factories that already sew stretch fabric and run the seams your style needs. Put the seam types in the brief; the quote confirms them.
For a first order, 8–12 weeks from brief to delivery: 2–4 weeks of sampling, 4–6 weeks of bulk production after you approve the sample, then 1–5 days of ground shipping in the lower 48.
Not to send a brief. For stretch garments it matters more than usual, though: measurements, negative ease and seam types decide the fit. Our tech pack is $79 per style, delivered in 3–5 working days with 2–3 revision rounds.
One brief can cover several products. Tick them all on the form and we place each style with the right US factory.
Activewear is ticked for you. Add the quantity, then finish the brief in two minutes. We reply within 24 hours.
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