Custom Activewear Manufacturer — Send a Sketch, Sign Off the Sample, Track Your Bulk
Start from a finished tech-pack, a competitor’s sample, or a sketch. You’ll see costed fabric options first, then a sample to approve stitch by stitch — and bulk is cut against that sealed sample, with inspection records you can pull at any stage. Full service lineup →
Send a tech-pack → costed reply with fabric options in 24 hours · NDA signed before you share a file · Every sample ships with its own QC photos
Custom Activewear Manufacturer Tolerances
The six tolerances we measure on every PO — copy them into your supplier scorecard.
Rolling 12-month output across all lines, with single-PO room of 50,000–100,000 pieces.
Schedule log + delay notes reviewable under NDA for active buyers.
Measurement, defect photos and packing records prepared per PO.
Fabric drifting past that line from your lab dip never reaches the cutting table.
Current and documented — certificate numbers and PDFs live on the About page.
Not per size. Split XS-XXL however your size curve reads — full policy on the FAQ.
Every PO ships with three records: AQL sampling-inspection report, spectrophotometer color log, and per-batch GSM measurement against your tech-pack.
Every shipment includes a per-batch sampling-inspection report and a spectrophotometer colour log. Pull them at any stage.
Custom Activewear Product Families
Four core families plus accessories — covered by 12 production lines (4 sublimation · 5 cut-and-sew · 3 team-set), so a multi-family PO ships under one date.
Training & Performance
High-stretch performance pieces — anti-pilling, moisture-wicking, four-way stretch builds for studio and gym SKUs.
View Family →
Athleisure / Lifestyle Fit
Heavier-weight knits and looser fits for off-gym wear and lounge collections.
View Family →
Team & Club Apparel
Sublimated team sets with number, name, crest personalization built into the pattern — driven by your roster CSV.
View Family →
Outdoor / Running
Wind-blocking shells, lightweight running tights, technical singlets for trail and road brands.
View Family →
Accessories
Cut-and-sew accessories matched to your main collection's fabric and dye lot.
View Family →Activewear we manufacture by sport & discipline
Yoga ApparelSquat-proof yoga & studio activewear
Gym ClothingAbrasion-tested gym training wear
Cycling ApparelAero race-fit cycling kit
Soccer ApparelSublimated soccer team kits
Basketball ApparelReversible basketball uniforms
Custom StreetwearHeavyweight athletic streetwear
Swimming ApparelChlorine-resistant swimwear & team suits
Golf ApparelMoisture-wicking polos & performance layers
Fishing ApparelUPF sun-protection shirts & vented shorts
Equestrian ApparelStretch riding tights & show shirts
Tennis ApparelQuick-dry court dresses, polos & skorts
Hockey ApparelSublimated field & ice hockey kits
OEM, ODM & Private Label Manufacturing Services
Eight service tracks — pick one or combine on the same PO; all six print & embroidery processes (sublimation, DTG, silicone, 3D embossed, flat embroidery, heat transfer) run in-house and combine on a single PO.
ODM
Pick from our pattern library, swap color, fabric or logo, skip the pattern-making cycle.
See service spec →Private Label
Your hangtag, care label, polybag and master carton — full label kit assembled by us.
See service spec →Small-Batch Sampling
One piece per sample, sewn in our own sample room before any bulk commitment.
See service spec →Custom Print & Embroidery
Sublimation, DTG, silicone, 3D embossed, flat embroidery, heat transfer — all in-house.
See service spec →Team Customization
Per-piece number, name, crest, sponsor block driven by your roster CSV.
See service spec →Tech-Pack & Pattern
No tech-pack yet? Our 16 pattern-makers build one from a reference sample or your sketch.
See service spec →Wholesale Program
Repeat-order programs for distributors and resellers — tiered pricing and reserved line capacity for standing SKUs.
See service spec →
First-PO checklist + service-track routing
Send six inputs on the left; match your situation to a track on the right.
Send these 6 inputs for a costed reply in 24 hours
- Tech-pack PDF, a reference sample or a sketch
- Size curve split across XS–XXL (or your usual percentages)
- Target unit count and how you want it split across sizes
- Fabric preference or “open to recommendation”
- Delivery window (FOB or CIF date)
- Cert markets you ship into (US / EU / AU / other)
Match your situation to a service track
- “I have a tech-pack and own colorway” → OEM (Cut-and-Sew)
- “No tech-pack but a reference garment” → Tech-Pack & Pattern → OEM
- “Want a proven block, just rebrand” → ODM
- “Existing blanks, need full label kit” → Private Label
- “One physical sample first, no bulk commit yet” → Small-Batch Sampling
- “Team kit with roster CSV → background number / name” → Team Customization
Activewear Factory Capacity Datasheet
Copy these rows into your supplier scorecard.
Want the production numbers before sales calls?
One-page PDF capacity datasheet — direct download, no email gate. Forward it to your sourcing director or operations lead.
No form. Direct PDF, 280 KB. Updated quarterly.
Common Activewear Manufacturing Problems Solved
Six problems sourcing directors keep flagging — each row shows the industry-standard answer next to ours, with the tolerance numbers attached.
Activewear Sourcing Process: Tech-Pack to Bulk
Five checkpoints from first email to delivered cartons — the full first-order walkthrough lives in our manufacturing process guide, timelines on the FAQ.
Step 1 · Inquiry
- You send: spec / tech-pack OR reference sample (no tech-pack? we build one)
- Berun returns: a written RFQ covering service track, timeline and suggested fabric options
- Price: free (no obligation)
Step 2 · Sample
- You send: the sample fee confirmed on your RFQ + lab dip color spec
- Berun returns: 1-piece sample + pattern + fabric swatch + spectrophotometer lab dip match
- Price: sample fee only, as quoted
Step 3 · Approval
- You sign off: pattern + fit + fabric + color
- Berun returns: locked tech-pack + PO confirmation + 30% deposit invoice
- Price: 30% deposit on PO total
Step 4 · Bulk Production
- You receive: WIP photos at cutting / mid-production / pre-shipment
- Berun runs: cut → sew → print/embroidery → pre-shipment batch QC
- Price: balance reminder at AQL pass
Step 5 · Delivery
- You receive: pre-shipment QC report + packing photos + shipment ID
- Berun ships: FOB or CIF per PO + 70% balance due on BL copy
- Price: 70% balance on BL
Activewear Manufacturer Certifications
Five certifications on file — request the PDFs by name.
OEKO-TEX
BSCI
WRAP Gold
GRS
Higg FEMAll five are current and audit-backed; the certificate numbers, scopes and preview scans are documented in full on the About page — or ask for any PDF by name during your RFQ.
Custom Activewear Manufacturer Case Studies
Four ICP profiles below (sourcing director · gym chain owner · DTC founder · sport team manager) — each card lists PO size, lead time, and the inspection record handed to that buyer.
ICP-A · Sourcing DirectorICP-A · US athleisure brand
First PO across performance leggings and sports bras
Performance leggings + sports bras. Lab dip approved first round; bulk delivered against the sealed sample; reorder triggered at scale on the same lab dip lane.
Cut our third-party inspection budget — every PO carries an AQL report.
ICP-A + C bridgeICP-C · EU DTC athleisure brand
Pilot launch across multiple colorways, size-curve split
Performance tees + joggers across multiple colorways. Entry quantity cut against the buyer's actual XS-XXL size curve, not multiplied per size. Reorder triggered after the sell-through window.
Honest size-curve math saved launches the previous factory had quietly killed.
ICP-B · Studio ChainICP-B · US fitness chain (multi-location)
Annual trainer uniform reorder, multi-year continuity
Trainer tees + branded zip-up jackets. Spectrophotometer log confirms color preserved against the original lab dip across reorder years; fabric outside ΔE 1.0 is rejected at receiving.
Year-over-year reorders match — no scrap, no member complaints.
ICP-D · Team CoachICP-D · Club / box team
Team sublimated jerseys driven by roster CSV
Custom team set (number + name + crest) shipped on the team-customization lead-time bracket of 18–25 days, with sponsor block added on amend. Game-day delivery date reserved at PO confirmation.
Roster CSV in, sublimated jerseys out on the published team-customization window.
Sourcing Director Reviews of Our Manufacturing
Three buyer quotes captured after the third PO — each names the operational problem that drove them to switch.
Two factories ago, batch-to-batch GSM drift was killing our retail performance. We moved several SKUs to Berun. Lab dip passed first round; bulk delivered against the sealed sample; the pre-shipment AQL report comes with every PO. We cut our third-party inspection budget.
— Senior sourcing director, US ICP-A athleisure brand
Most factories quote a per-SKU minimum but multiply it by every size on the curve. That math has killed launches before. Berun cut our first PO across XS-XXL exactly as our sales data read. They send a monthly OTD report unprompted; I forward it to our CFO every month.
— Founder, EU ICP-C DTC athleisure brand
Annual trainer uniform reorder is non-negotiable — if last year's batch and this year's batch don't match in person, members ask why. Berun rejects fabric past ΔE 1.0 at receiving and pulls the original lab dip for every reorder. The spectrophotometer log proves the color carries across years. No batch-to-batch surprises, no safety stock for color compensation.
— Operations director, US ICP-B fitness chain (multi-location)
Global Activewear Manufacturer Markets
Eight years, five regions, five buyer types.
Markets shipped · % of 2024 volume
Client type mix · % of active accounts
Custom Activewear Manufacturing FAQ
Eight questions sourcing directors and first-time founders ask before PO 1.
Where do the order minimum, sample and pricing policies live?
All commercial policy — minimum quantities, how the size curve splits, sample fees and crediting, payment structure — is maintained in one authoritative place: the FAQ page. Whatever it says there is what appears on your quotation; nothing changes between webpage and PO.
Related: Common Problems Row 2 ↑
Can we audit the factory before committing to a first order?
Yes — book a virtual factory tour or an on-site visit through the contact page. You can walk the cutting room, sewing floor, sublimation hall and the testing lab, and active buyers can review our shipment logs under NDA. The full floor-by-floor walkthrough is documented on the About page.
I don't have a tech-pack — can I still work with you?
Yes. Our 16 pattern-makers can build a tech-pack from a reference sample (a garment you already own) or a sketch, then we proceed exactly the same way as a client who brought their own tech-pack. Fee and turnaround are on the tech-pack service spec.
Related: Production Services Card 7 ↑ · Sourcing Process Step 1 ↑
What does your inspection standard actually mean for my order?
AQL stands for Acceptable Quality Limit — the inspection sampling rate per ANSI/ASQ Z1.4. In plain English: we randomly inspect a statistically valid sample of pieces from your batch (typically 80-200 pieces depending on PO size) and check for defects. The level we run (see the scorecard up top) is what retailers like Target and Costco require. We share the inspection report with every shipment.
What's your on-time delivery rate? Can I see evidence?
Our rolling 12-month OTD sits in the scorecard at the top of this page. We log every shipment with promised date, actual date, and delay reason. The full log is reviewable under NDA for active buyers. We also send monthly OTD reports to repeat clients without being asked.
Related: Capacity Datasheet Row 9 ↑ · Common Problems Row 4 ↑
Difference between OEM, ODM, and Private Label?
In one line each: OEM builds from your design and spec; ODM starts from our pattern library so you launch faster; Private Label layers your hangtag, care label and packaging on top of either, as an add-on. The full track-by-track breakdown lives on the services page.
Related: Production Services Cards 1, 2, 3 ↑
Payment terms and FOB/CIF options?
Standard PO terms: 30% deposit on PO confirmation, 70% balance on BL (bill of lading) copy. FOB is default (you arrange shipping from our nearest port). CIF available on request (we arrange shipping to your destination port). For active buyers with repeat orders, we offer NET-30 on the balance.
How do you handle batch-to-batch color consistency?
Every PO starts with a lab dip — your approved color sample. We measure ΔE (color delta) against the lab dip using a spectrophotometer at three checkpoints: fabric receiving, mid-production, and pre-shipment, with fabric failing the lab-dip tolerance rejected at receiving. The lab dip is stored in your client master file and pulled for every reorder — so a reorder 6 months later matches the original.
Related: 5-Sec Disqualifier Stat 2 ↑
Have another question? Send it to [email protected] — we reply within 1 business day.