At MODENLY, our specialty is luxury custom tracksuits that fit companies, teams, and brands for their specific demands. Choosing the correct fabric is crucial to guarantee comfort, durability, and performance whether your search is for tracksuits for retail, sporting teams, or corporate branding.

When developing tracksuits for various uses, breathability, flexibility, weight, and general feel—all important considerations—are affected by the fabric choices. For activewear, some materials have better moisture-wicking qualities; others have a softer, more premium feel for casual wear. But given the variety of fabrics now on the market, how would you decide on the ideal one for your own tracksuits?

We divide the most often used fabric options for custom tracksuits in this guide, stressing their main advantages, best use cases, and considerations for a bulk order. This page will guide you in choosing lightweight tracksuits for warm weather, high-stretch materials for sports wear, or cozy fleece for winter wear.

Key Factors to Consider When Choosing Fabric for Custom Tracksuits

When designing custom tracksuits, fabric selection is one of the most crucial decisions that directly impacts comfort, durability, and performance. Whether for retail fashion, corporate branding, or sports teams, the proper material guarantees that the tracksuits complement their intended use. Before deciding, one has to take various important things into account, from breathability and stretch to weather resistance and lifetime.

Comfort: Prioritizing Wearability for Different Uses

Given how often people will wear a custom tracksuit, comfort is among its most crucial features. Different tracksuit uses call for different degrees of softness, breathability, and insulating power.

The fabric of high-performance sportswear should be breathable, lightweight, moisture-wicking to keep athletes cool and comfortable throughout physical exercise. Because polyester and spandex mixes can stretch and enable a full range of motion, they are rather popular.

A cotton-blend tracksuit offers a light, airy feel that accentuates daily comfort for business or leisure use. Companies ordering tracksuits for staff uniforms or promotional events should give textiles comfortable for all-day use top priority.

A fleece-lined or thermal fabric choice guarantees warmth and insulation while nevertheless keeping a fashionable appearance in cold-weather circumstances. Winter training, outdoor activities, and team gear call for these fabrics.

Breathability: Keeping Cool During Activity

Custom tracksuits meant for sports teams, gym wear, or active lives depend on breathability. Made from moisture-wicking fabrics, tracksuits used for training, exercises, or outdoor activities should help to control body temperature and stop overheating.

For best ventilation and perspiration build-up prevention, polyester mesh and microfiber textiles are excellent choices. By drawing moisture away from the body, these fabrics help the wearer to remain dry and comfortable. Ideal for high-performance sports, spandex, often known as elastane combinations improve moisture management and flexibility even more.

Though breathable, cotton-based materials often collect moisture rather than wick it away. They are therefore less suited for rigorous exercise but a great option for casual and leisure tracksuits. Companies choosing fabric should take into account the planned use of the tracksuit to guarantee the optimal mix of breathability and performance.

Durability: Ensuring Longevity for Bulk Orders

For companies ordering plenty of bespoke tracksuits, durability is a major factor. Even after several washings and extended wear, a good tracksuit should keep its structure, color, and shape.

For team uniforms, business wear, and retail collections, polyester blends are a great choice since they are incredibly robust and resistant to shrinking, fading, and wrinkle development. Mixes of cotton-polyester provide better wear resistance, hence lowering shrinking while preserving suppleness.

Tracksuits coated with fleece provide more warmth and durability for winter wear or outdoor activities. These materials resist regular washing and long-term wear so the tracksuit stays comfortable and fashionable over time.

Selecting a fabric that keeps its quality even with regular use guarantees companies provide a long-lasting good supporting brand dependability.

Stretch & Flexibility: Enhancing Mobility

Stretchability is key for athletic and performance-based tracksuits. Warm-ups, training sessions, and regular activewear are perfect for fabrics with built-in flexibility since they let a complete range of motion.

Maximum mobility is ensured by spandex or lycra mixes, therefore guaranteeing that the tracksuit does not limit movement. High-intensity exercises like jogging, yoga, or gym sessions benefit especially from four-way stretch fabrics.

For companies who need tracksuits for both casual and performance-based usage, cotton-poly mixes provide reasonable adaptability. Choosing elastic materials guarantees higher use if the tracksuit is intended for sports, dancers, or fitness buffs.

For sports teams and athletes, moisture-wicking polyester or spandex blends provide optimal performance. For corporate branding or casual wear, cotton-polyester blends offer a balance between comfort and durability. For cold-weather training or outdoor events, fleece-lined tracksuits provide warmth and insulation. Want to showcase your brand with custom tracksuits? Get a free design consultation and see how we can bring your vision to life!

Most Popular Fabric Options for Custom Tracksuits

Choosing the right fabric for custom tracksuits can significantly impact comfort, durability, and overall performance. Selection of a fabric that fits the intended usage of the tracksuit is crucial since different materials provide different degrees of breathability, stretch, and insulation. The most often used fabrics are broken out below together with their benefits, ideal uses, and any negatives.

Polyester – The Go-To Fabric for Sportswear

Custom tracksuits—especially those for sports teams, fitness companies, and wearable collections—especially feature polyester among the most often used fabrics. Athletes and anyone who lead regular physical activity will find this synthetic fabric perfect as it is lightweight, durable, and moisture-wicking.

By drawing moisture away from the skin, polyester tracksuits ensure that wearers remain dry and comfortable and assist control body temperature. Polyester is also quick-drying and wrinkle-resistant, which makes it a great choice for performance wear and team uniforms needing frequent cleaning. Though polyester has great durability, it might not be as soft or breathable as natural materials like cotton.

High-performance sportswear, gym gear, and professional team tracksuits—where durability and perspiration control rule—this fabric is ideal.

Cotton – Comfortable and Breathable for Casual Wear

Natural fabrics prized for their softness, breathability, and quality feel are cotton. Although cotton doesn’t wick as moisture-wise as polyester, it is rather comfortable and a great option for casual and leisure tracksuits. Corporate loungewear, promotional clothing, and fashion-forward athletic wear—where comfort rules over high-intensity performance—use this material most often.

Those with sensitive skin would find cotton tracksuits perfect since they are hypoallergenic and skin-friendly. They also present a high-end look, which qualifies for collections of luxury or premium brands. Cotton is less perfect for intensive exercise or humid surroundings, though, since it absorbs moisture instead than wick it away.

Where comfort and looks are paramount, this fabric is ideal for corporate tracksuits, casual wear, and elegant retail clothing.

Cotton-Polyester Blend – The Best of Both Worlds

Combining the best features of both materials, a cotton-polyester mix provides comfort, durability, and moisture management. Popular for multifarious use, this mix keeps cotton’s softness while adding polyester’s toughness and moisture-wicking qualities.

Corporate attire, school teams, and promotional goods would all benefit from cotton-polyester blends’ wrinkle-resistant, shrink-resistant, and low maintenance qualities. Although they still offer great comfort, these blends have modest moisture-wicking properties, which makes them more appropriate for activewear than 100% cotton.

For tracksuits meant for both casual and performance-based wear, this fabric offers flexibility across many sectors.

Fleece – Best for Warmth and Comfort

Winter sports, outdoor activities, and cold-weather situations call for fleece-lined tracksuits as great insulators while yet preserving a soft and pleasant feel. For tracksuits meant for winter training or outdoor business wear, fleece is a synthetic fabric well-known for trapping heat and preserving warmth.

Superior softness makes fleece tracksuits pleasant for all-day wear. They are less suited for high-intensity exercises, nevertheless, because they are less breathable than polyester or moisture-wicking combinations. Furthermore, fleece tracksuits are often heavier, which would not be perfect for those seeking for light-weight sportswear.

Where warmth and insulation are crucial, this material is ideal for seasonal sporting uniforms, cold-weather sports teams, and corporate outdoor wear.

Spandex or Lycra Blends – For High-Performance Tracksuits

Spandex or Lycra mixes give improved mobility and athletic performance for tracksuits that call for maximum flexibility and stretch. Professionals in fitness, dancers, and athletes who require complete range of motion throughout their activities will find these textiles perfect.

High-performance sportswear prefers spandex-infused tracksuits because they fit tightly and contouringly. These fabrics withstand wear and tear, therefore ensuring that tracksuits keep their elasticity and form even after long use. But if not mixed with softer materials, spandex or Lycra blends can feel tight; they also tend to be more costly than ordinary polyester or cotton choices.

Athletic teams, fitness companies, and movement-based events—where stretchability and mobility are most important—should make most use of this fabric.

For sports teams and activewear, polyester or spandex blends provide optimal durability and flexibility.For corporate branding and lifestyle apparel, cotton or cotton-polyester blends offer comfort and versatility.For winter apparel, fleece-lined tracksuits provide warmth and insulation.For professional athletes, spandex-infused materials offer maximum stretch and mobility.

How Fabric Choices Affect Customization Methods

Selecting the appropriate fabric for custom tracksuits affects not only comfort and durability but also the best methods of customizing logos, branding, and design components. Different materials respond differently to embroidery, screen printing, heat transfer, and sublimation, therefore affecting color brightness, durability, and general design attractiveness. Choosing the incorrect customizing technique for a given fabric could cause distortion, peeling, or fading, therefore lowering the general quality of the tracksuit. We investigate below how different materials influence different customizing methods.

Embroidery: Best for a Premium and Durable Look

One of the most durable customizing techniques is embroidery, which gives premium retail tracksuits, sports team clothing, and corporate logos textured, high-end finish. Direct sewing of the stitching into the fabric guarantees long-lasting durability and fade or peeling resistance.

On thicker, more structural fabrics that can support the weight of the stitches without puckering or distortion, though, embroidery works best. For lightweight, high-stretch materials like spandex, the stitching could cause the cloth to warp.

Best Fabric Choices for Embroidery:

• Cotton-polyester blends – Provides a stable surface for clean and precise stitching.
• Fleece-lined tracksuits – Can support embroidery well, especially for logos on thicker materials.
• Thicker polyester fabrics – Suitable for embroidered logos without causing excessive distortion.

Pros of Embroidery:

• Highly durable and long-lasting, resistant to washing and wear.
• Gives a high-end, professional look, ideal for corporate branding and premium apparel.
• Works well for logos and team insignias, creating a bold, raised effect.

Cons of Embroidery:

• Not suitable for lightweight or stretchy fabrics, as it may cause puckering.
• More expensive than printing methods, especially for large designs.

Best for: Corporate tracksuits, team apparel, and high-end custom collections requiring a premium branding effect.

Screen Printing: Best for Bold and Cost-Effective Branding

Perfect for mass orders of bespoke tracksuits, screen printing is a bright and reasonably priced customizing tool. Applying ink through a stencil this method produces strong, long-lasting prints. It is particularly well-suited for branding sports teams, promotional apparel, and corporate tracksuits that require clear and visible logos.

With screen printing, polyester and cotton-polyester combinations perform best since they hold ink effectively without absorbing excessive moisture. For complex designs including gradients or fine details, screen printing is not appropriate, though.

Best Fabric Choices for Screen Printing:

• Polyester tracksuits – Ensures ink adhesion and prevents fading over time.
• Cotton and cotton-poly blends – Provides a smooth surface for clear and vibrant printing.
• Fleece tracksuits – Works well for larger printed designs but may require multiple ink layers for full opacity.

Pros of Screen Printing:

• Cost-effective for large orders, making it ideal for team and event tracksuits.
• Provides bold, high-contrast prints, ensuring strong brand visibility.
• Works well for simple, solid-color logos and text-based designs.

Cons of Screen Printing:

• Not suitable for highly detailed or intricate designs, as it struggles with fine lines and color gradients.
• Ink can crack or fade over time, especially with frequent washing.

Best for: Promotional tracksuits, bulk team orders, and corporate branding that requires high-visibility logos at an affordable cost.

Heat Transfer Printing: Best for Intricate and Multi-Color Designs

Heat transfer printing is heat and pressure application of pre-printed vinyl graphics onto cloth. Fashion companies, custom team uniforms, and unique retail collections all find this approach ideal for custom tracksuits needing highly intricate, full-color designs.

On smooth synthetic materials, heat transfer printing performs effectively to guarantee correct pattern adhesion and flexibility. But since the design could peel over time with too much washing, it is less robust than embroidery or screen printing.

Best Fabric Choices for Heat Transfer:

• Polyester and spandex blends – Smooth surfaces allow for high-definition prints.
• Cotton-poly blends – Provides a stable base for heat transfer designs.
• Lightweight athletic tracksuits – Ensures flexibility and detail in branding.

Pros of Heat Transfer Printing:

• Perfect for intricate graphics, multi-color designs, and detailed branding.
• Provides flexibility and stretch, making it ideal for high-performance athletic wear.
• Great for small-batch customization, allowing businesses to create limited-edition tracksuits.

Cons of Heat Transfer Printing:

• Less durable than embroidery or screen printing, as designs may peel over time.
• Not ideal for bulk production, as each piece requires manual application.

Best for: Customized fashion tracksuits, small-batch branding, and unique retail designs that require high-detail prints.

Sublimation Printing: Best for All-Over Prints and High-Resolution Designs

Using sublimation printing—a method whereby dye is directly injected into synthetic fabrics—vibrant, full-coverage graphics created will not fade, break, or peel. For companies trying to create unique tracksuits with all-over patterns, seamless designs, or intricate graphics, it is perfect.

But since the ink attaches straight to synthetic fibers, sublimation only works on polyester-based materials. Tracksuits made of cotton or cotton-blend are incompatible with it.

Best Fabric Choices for Sublimation Printing:

• 100% Polyester – The only fabric that fully absorbs sublimation ink for long-lasting designs.
• Polyester-spandex blends – Retains color vibrancy while allowing for stretch and flexibility.

Pros of Sublimation Printing:

• Long-lasting and fade-resistant, making it ideal for high-performance sportswear.
• Allows for unlimited color variations, including gradients and detailed patterns.
• Creates a smooth, seamless design, as the ink integrates directly into the fabric rather than sitting on top.

Cons of Sublimation Printing:

• Only works on polyester-based fabrics, limiting material choices.
• More expensive for small-batch production, as it requires specialized printing equipment.

Best for: High-end athletic tracksuits, professional eSports apparel, and bold retail collections featuring all-over designs.

Ensuring a seamless transition into a larger product range by means of supply chain efficiency optimization and collaborating with a manufacturer providing flexible production options guarantees scalability.

Conclusion: Custom Tracksuits

Choosing the correct fabric for custom tracksuits is a vital choice that affects general performance, comfort, and durability. Knowing the strengths of each fabric can help you make sure your tracksuits satisfy the expectations of your business whether your choice is lightweight polyester for breathability, a cotton mix for casual use, or spandex for high-performance athletic wear.

Designed to fit the particular needs of your company, at MODENLY we provide premium customizing options including a wide selection of fabric choices, embroidery, and printing processes. Should you wish to order bespoke tracksuits in bulk, our staff can assist you in choosing the best materials and techniques for your company. Get in touch with us today to request fabric samples and get a competitive quote for your custom tracksuit order!