In today’s inclusive fashion era, plus size activewear is one of the fastest-growing categories. Yet many B2B buyers like Ron—who targets private label opportunities in North America—struggle to find factories that can deliver quality, style, and affordability at scale. Sourcing activewear for curvier bodies isn’t as simple as upsizing standard fits.
To source plus size activewear competitively, brands must focus on experienced factories, performance-grade fabric sourcing, scalable patterns, and negotiation of MOQs and Incoterms that maximize value without sacrificing quality.
At Fumao Clothing, we specialize in full-package solutions for curvy activewear ranges. With over a decade of export experience and five production lines, we’ve helped multiple clients scale up without overpaying.
Which Fabrics Are Best for Plus Size Activewear?
Choosing the right fabric is crucial for both function and price. Plus size activewear must stretch without going sheer, offer good recovery, and hold shape after repeated wear and wash.
Look for cost-effective, performance fabrics like nylon-spandex blends, RPET knits, and interlock weaves with soft handfeel and high elasticity.
Why Is Nylon-Spandex the Industry Standard?
Nylon-spandex blends offer smoother surfaces, better stretch recovery, and higher durability than basic polyesters. For plus sizes, this ensures garments contour well without excessive compression or rolling.
We source 75/25 and 80/20 blends with four-way stretch for leggings, sports bras, and fitted tops. These blends also absorb color beautifully and last longer under tension.
Explore nylon vs polyester for sportswear or learn about spandex in activewear.
Can Recycled Fabrics Still Be Affordable?
Yes. Recycled polyester (rPET) blends are now competitively priced, especially when sourced in bulk. Brands can access sustainability claims without paying luxury fabric premiums.
We offer GRS-certified rPET fabrics for plus size ranges with price points under $3.5/meter at MOQs of 800–1000 pieces.
See GRS-certified fabric options or read about cost-effective sustainable textiles.
How to Optimize Fit and Patterns for Plus Sizes?
You can’t just scale up small-size patterns. True plus size design involves reshaping, rebalancing seam lines, adjusting rise and coverage, and using curved grading increments.
Invest in factories with plus-size grading experience and access to fit models across the 1X–5X spectrum to avoid costly resampling.
What Are the Key Fit Considerations?
- Rise & waistband: High-waisted designs need reinforced seams and wider elastic for tummy control.
- Thigh & hip shaping: Avoid overcompression by increasing ease at key stress points.
- Bust and shoulder alignment: Especially in plus-size sports bras, strap placement and cup shaping are critical.
At Fumao, we use 3D grading tools and test on real plus-size fit models before bulk production.
Check grading rules for plus-size patterns or see why pattern blocks must differ.
Can 3D Fitting Tools Reduce Costs?
Yes. Technologies like CLO3D allow digital testing of garments on plus-size avatars, saving time on physical prototyping. This improves communication and gets faster approvals—important when every sample costs money.
We offer 3D previews for clients to review fit, drape, and proportion before cutting fabric.
Explore CLO3D applications in apparel or read about 3D sampling cost savings.
Where to Find Factories That Specialize in Plus Sizes?
Not every factory has the technical skills or mindset to handle curvy ranges. You need a partner that sees plus-size as a core category, not a side job.
Factories specializing in plus sizes often maintain customized patterns, larger cutting tables, high-torque sewing machines, and seam testers for performance garments.
How to Vet Plus Size Capability in a Factory?
Ask to see previous plus-size samples. Review their size range for existing clients. Ask whether they use fit models over 2XL or if they only extrapolate from size M. You can also request a digital factory tour to see cutting, stitching, and packing lines.
At Fumao, our plus size program includes full-package leggings, tops, and tracksuits from 1X to 5X with tech pack support.
See questions to ask your factory or read how to assess sizing capacity.
Is It Better to Work with OEM or ODM?
OEM (Original Equipment Manufacturing) means you provide the design and spec—ideal for brands with established styles. ODM (Original Design Manufacturing) offers ready-to-sell styles with custom labeling—faster, cheaper for small brands.
We offer both modes and suggest ODM for first-time buyers who want low-risk plus size lines.
Understand OEM vs ODM differences or review which is right for your business.
How to Negotiate Better Prices Without Sacrificing Quality?
Pricing isn’t just about volume—it’s about choosing the right trims, construction, and shipping terms. You can still get top-tier quality at lower costs with the right setup.
Strategies include simplifying SKUs, batching fabric types, using DDP terms, and securing longer production windows to avoid peak season surcharges.
What MOQ and Price Points Are Realistic?
For plus size activewear, factories like ours typically offer:
- MOQs: 600–800 units per style per color
- Unit Cost: $4.90–$7.80 FOB depending on fabric and trims
- DDP Cost to USA: $6.20–$9.10 including duties and shipping
The bigger your PO, the more leverage you have over price per piece.
Check MOQ strategies for small brands or explore average cost breakdown in activewear.
Should You Choose DDP or FOB Terms?
DDP (Delivered Duty Paid) gives cost certainty—ideal for clients like Ron who want simplicity. We calculate full landed cost including customs, and handle all logistics.
FOB (Free on Board) is cheaper upfront but requires buyers to manage shipping, customs, and insurance.
Understand Incoterms in clothing sourcing or compare FOB vs DDP in China-US trade.
Conclusion
Sourcing plus size activewear at competitive prices isn’t about cutting corners—it’s about choosing partners who understand curvy fit, material performance, and scalable production. With the right supplier, you can deliver stylish, functional garments that keep customers happy while protecting your margins.
At Fumao Clothing, we help North American clients like Ron launch inclusive activewear lines that look great and feel even better. If you're ready to scale your plus-size sportswear program, contact our Business Director Elaine at elaine@fumaoclothing.com for fabric samples, design support, and a custom quote.
