Custom Tracksuit Manufacturing: Design, Fabrics, and Production Guide

Tracksuits are everywhere right now, and not just at the gym. The tracksuit has crossed over from athletic wear into streetwear, into luxury fashion, and into everyday casual wear in a way that would have seemed odd fifteen years ago. From the classic Adidas three-stripe aesthetic to the high-fashion Gucci velour sets, the tracksuit is one of the most versatile product categories a clothing brand can work in.

We produce tracksuits for brands across all these segments, and the manufacturing considerations vary significantly depending on which market you are targeting. A performance tracksuit for a running club has completely different requirements from a premium velour set for a streetwear label. This guide will walk you through the key decisions at every stage.

The Main Tracksuit Categories and Their Manufacturing Requirements

Before diving into fabric and construction specifics, it helps to be clear about which category you are designing for, because this shapes almost every subsequent decision.

Performance athletic tracksuits are designed for actual training — warming up before competition, post-training recovery, or light exercise. These prioritize moisture management, stretch, breathability, and durability. Common fabrics are polyester or polyester-spandex blends in the 200 to 260 GSM range. Think the kind of tracksuit you see athletes wearing at the Olympics before their event.

Lifestyle and athleisure tracksuits are worn at the gym but also everywhere else — running errands, casual social settings, travel. The design skews fashion-forward with color blocking, contrast details, and a cleaner silhouette. Fabrics include French terry, modal blends, and scuba fabric. The GSM range is wider, typically 220 to 320 GSM.

Streetwear tracksuits are about cultural identity and brand expression, not athletic function. Heavy weight fabrics, oversized silhouettes, bold graphics and branding, premium materials like velour or heavyweight fleece. GSM typically 300 to 420 GSM. These have the highest price points and the most room for distinctive design.

Premium and luxury tracksuits use elevated materials — cashmere blends, high-end velour, technical stretch wovens — and precision tailoring. Construction standards are much tighter. Seam allowances, lining details, and finishing are critical.

Fabric Options for Custom Tracksuits

The fabric decision is the single biggest driver of the tracksuit's end character. Here are the most commonly used options:

French terry: The classic tracksuit fabric. A knit construction with loops on one side and a smooth surface on the other. The looped interior traps air for warmth while the smooth exterior drapes cleanly. Available in cotton, polyester, and cotton-poly blends. Cotton French terry (typically 300 to 380 GSM) is the choice for lifestyle brands; polyester French terry is better for performance applications.

Fleece (brushed back): Available in varying weights from 280 to 450 GSM. The interior is brushed to create a soft, fuzzy texture. Heavier fleece tracksuits have a premium, substantial feel. Popular in streetwear. The downside is that fleece can pill over time, especially with lower-quality yarn.

Tricot (polyester knit): The classic material for athletic warm-up suits. Lightweight (typically 160 to 200 GSM), smooth hand feel, excellent drape. Shiny or matte finishes both available. If you want the classic soccer warm-up tracksuit look, this is the fabric.

Scuba fabric: A double-knit polyester-spandex construction with a smooth, neoprene-like appearance. Very popular in contemporary athletic and athleisure design. Has good structure without being stiff, excellent recovery. Typically 250 to 310 GSM.

Velour: A cut-pile knit fabric with a soft, plush surface. The iconic fabric for retro and luxury tracksuits. Cotton velour has a matte richness; polyester velour has more sheen. Heavy, luxurious feel. Not a performance fabric but excellent for lifestyle and fashion positioning.

Jacket Construction and Design

The tracksuit jacket can take several forms, each with different construction requirements.

Full-zip jacket: The standard. A center-front zipper running the full length of the jacket, with a collar (mock neck, stand collar, or small lapel) and typically two side pockets (either welt or zip). The zipper quality matters enormously — YKK is the industry standard for quality, and I always recommend specifying YKK zippers in your tech pack. Off-brand zippers catch, fail at the slider, and generate customer complaints.

Quarter-zip pullover: No full opening — just a zipper at the throat for ventilation. A more athletic look, popular in performance tracksuits. Simpler construction than a full-zip.

Snap-button tracksuit: Uses snaps instead of a zipper, creating the characteristic popping sound. The classic Adidas aesthetic. Adds a bit of complexity to manufacturing but creates a distinctive feel and sound that customers love.

For all jacket constructions, specify your ribbing carefully. Ribbed cuffs and hem bands need to have the right stretch-to-recovery ratio — too loose and they sag, too tight and they constrict. Typically a 1x1 or 2x2 rib knit with a high spandex content works well.

Jogger Pants Construction

The pants half of the tracksuit set has its own set of decisions.

Waistband construction: The most important detail. Standard options are a drawstring waistband (folded fabric with a drawcord through a channel), elastic-only waistband, or a combination of both. For streetwear and lifestyle, exposed drawstrings with branded tips (aglets) are a nice design detail. For performance, a clean elastic-only band with no hardware is more appropriate.

Pocket options: Side pockets are standard. Specify whether they are slanted (more ergonomic) or straight. A zippered coin pocket on the right side is a popular add-on. Back pockets are optional and add construction complexity.

Leg opening options: Straight leg (clean, contemporary, easy to wear with any footwear), tapered leg (slim from knee to ankle, the most common athleisure cut), or jogger cuff (tapered with a ribbed ankle cuff — classic tracksuit style). Your target market and aesthetic should drive this choice.

Branding and Design Details

Tracksuits offer excellent canvas for branding. The most effective branding locations are the chest (left or center), the left leg below the hip, the back yoke, the sleeve, and the side tape if you are doing a racing stripe design.

For a cohesive tracksuit set, make sure branding placement is consistent between the jacket and pants — same position, same size, same application method. A tracksuit where the jacket logo is embroidered and the pants logo is a heat transfer, or where they are at different heights, looks unfinished.

Contrast piping or stripe tape down the outer leg and jacket sleeve is a classic tracksuit design element that elevates even simple styles. Specify the tape width, color, and attachment method (sewn into the seam versus applied on top of the seam) in your tech pack.

When you are ready to develop your custom tracksuit line, explore our sports wear catalog to see examples of tracksuits and sets we produce. For a detailed quote on your specific design, get a free quote — we start at 50 pieces per style and respond within 24 hours.