Custom Sportswear Manufacturer for Brands, Teams & Clubs
Different sports demand different patterns, fabrics, and constructions. We build each garment around how it will actually be used. A running singlet, a wrestling singlet, and a cycling jersey are all sportswear, and almost nothing about how they are built is the same. Different fabric weight, different seam, different pattern, and different fit through the shoulder.
A sportswear manufacturer that treats them as one category will send you a garment that fails in the first session. Mega Apparel is a custom sports apparel manufacturer producing kits for athletic brands, clubs, teams, gyms, schools, and distributors. We have been manufacturing since 2012; more than 2,000 clients have run production through our factory, and we start at 35 pieces per style.
Tell us the sport, not just the garment. Everything after that gets easier.
What Changes When The Sport Changes
Buyers usually arrive asking for a jersey or a pair of shorts. The useful question is what happens to that garment on the field.
| Sport | What the garment has to survive | How we build for it |
|---|---|---|
| Soccer / Association Football | Full match sweat load, sliding on turf, frequent washing | Lightweight poly mesh, sublimated numbers, reinforced side seams |
| Basketball | Overhead reach, arm friction at the armhole | Wide armholes, low-friction binding, mesh body for airflow |
| Running | Chafing over long distances, high sweat | Flatlock or bonded seams, light poly, mesh back panel, reflective trim |
| Cycling | Hours in a forward position, jersey riding up | Longer back panel, silicone gripper hem, rear pockets, full zip |
| Wrestling, MMA, and BJJ | Grabbing, pulling, and constant tension | High spandex knit, bar-tacked stress points, no loose trims |
| Gym and cross-training | Loaded movement, squat, and hinge | Four-way stretch, gusseted crotch, opacity checked under stretch |
| Racquet sports and pickleball | Rotation, quick lateral movement, sun exposure | Stretch woven, UPF finish, articulated sleeve |
| Volleyball | Diving, floor contact at hip and knee | Reinforced panels, longer hem, close fit that stays put |
| Esports and casual team wear | Long sitting, heavy branding, all-day comfort | Softer poly blend, full sublimation, relaxed block |
None of that is exotic. It is just the difference between a factory that makes sportswear and one that makes t-shirts in polyester. When you send a brief, tell us the sport, the level, and the climate. Those three things settle most of the spec before we talk about color.
Sports Clothing We Manufacture
Every piece is made to your tech pack. These are not blanks with a print pressed on top.
Custom Jerseys
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Soccer, basketball, baseball, hockey, and esports jerseys in poly mesh or interlock from 130 to 180 GSM, with full sublimation so names and numbers are part of the fabric rather than sitting on it.
Custom Sports Shorts
Woven and knit shorts from 5 to 11 inch inseams, with elasticated or drawcord waists, side pockets, mesh liners, and gusseted construction for open movement.
Custom Leggings and Tights
Nylon spandex and poly spandex at 220 to 280 GSM, high-rise waistband, flatlock or bonded seams, side pockets, and opacity checked under stretch before bulk.
Custom Sports Bras
Light, medium, and high support builds with power mesh back panels, removable pads, adjustable straps, and encased elastic under the bust.
Custom Tracksuits and Warm-ups
Matching jacket and pant sets in tricot, polyester twill, or brushed poly, with contrast piping, zip pockets, and ankle zips.
Custom Joggers and Sweatpants
French terry and performance fleece from 280 to 400 GSM, tapered or straight, with ribbed or elasticated cuffs and zip pockets.
Custom Tank Tops
Training tanks, stringers, running singlets, and wrestling singlets, each on its own block because the cut and the coverage rules are different.
Custom Performance Tees and Polos
Poly pique and jersey knit from 140 to 190 GSM with moisture wicking and UPF finishes for training, coaching staff, and club shop lines.
Custom Compression Wear
Compression tops, tights, and sleeves in 15 to 25 percent elastane knits, built to a target pressure rather than just a tight pattern.
Custom Sports Jackets and Windbreakers
Ripstop windbreakers, bonded softshells, and packable rain shells with taped seams and YKK zippers for sideline and travel kits.
Custom Sports Hoodies
Performance and cotton blend hoodies for warm-ups, travel days, and club shop sales, matched to the rest of your kit in color and trim.
Custom Socks and Accessories
Knitted sports socks with arch support and mesh venting, plus custom caps, headbands, bags, and towels, so a full kit ships in one carton.
Fabrics for Sportswear
Cotton belongs in club shop hoodies and travel wear, not in on-field kit. It absorbs sweat, holds it, gets heavy, and stays wet. Everything that plays gets built in a synthetic knit.
| Fabric | Weight | Used for | Why |
|---|---|---|---|
| Poly mesh and micro mesh | 120 to 160 GSM | Jerseys, panels, liners | Maximum airflow, very light, holds sublimation |
| Poly interlock | 150 to 190 GSM | Jerseys, performance tees | Smooth both faces, prints cleanly |
| Poly spandex jersey | 170 to 220 GSM | Training tops, polos | Stretch with quick dry |
| Nylon spandex | 220 to 280 GSM | Leggings, sports bras | Soft hand, strong recovery, opaque at correct weight |
| Four-way stretch woven | 180 to 240 GSM | Shorts, racquet wear | Stretch with a woven finish, wrinkle resistant |
| Tricot | 180 to 240 GSM | Tracksuits, warm-ups | Smooth face, classic sideline look |
| Performance fleece | 280 to 400 GSM | Joggers, hoodies | Warmth with wicking, brushed inner face |
| Power mesh | 150 to 200 GSM | Bra backs, vent panels | Open structure with support |
| Recycled polyester | Matches base fabric | Any polyester piece | Post-consumer recycled, GRS-certified stock available |
Finishes we apply on request: moisture wicking, quick dry, anti-odor and antimicrobial treatment, UPF 50+, cooling finish, water repellent, and brushed backing. Colors are matched to Pantone TCX, and the dye recipe stays on file, so a reorder in March matches the batch you took in September.
We Offer Printing, Embroidery, and Finishing.
Performance fabric does not take decoration the way cotton does. A heavy plastisol print on a stretch knit will crack in the first season. These are the methods that hold.
- All-over sublimation: The default for sportswear. Ink bonds into the polyester fiber, so there is no hand feel, nothing to crack, and no weight added to the stretch. Panels are printed before they are cut, which is why seam-to-seam graphics line up across the garment. White polyester base only, which is the trade-off.
- Heat transfer and silicone transfer for numbers, sponsor logos, and short-run additions on an existing garment.
- Stretch additive and water-based screen printing for placement graphics on knits.
- Embroidery on stabilized panels, usually chest, sleeve, and cap fronts, with backing so the stitch does not pucker the knit.
- Silicone and TPU raised badges, woven patches, and reflective print.
- Fabric dyeing and Pantone matched color development across a whole kit.
- Trims, YKK zippers, silicone grippers, custom drawcords, contrast binding, and bar-tacked stress points.
Send artwork as vector files, AI, EPS, or PDF, with Pantone TCX references. For sublimation, we return a full-scale panel layout for your approval before anything is printed.
Private Label and Packaging
Every order ships under your brand. Your customer should never see our name on the garment or in the carton.
We produce woven, satin, printed, and tagless heat transfer neck labels. Tagless is the usual choice in sportswear, because a stitched label sits directly against sweating skin. Care and content labels are printed with fiber content, country of origin, and care symbols in the format US retail expects under the FTC Care Labeling Rule, and we will print your RN number if you have one.
Packaging runs the same way. Branded poly bags, custom mailers, hang tags, and UPC or EAN barcodes applied per unit. For team orders we can bag and label each kit by player name so the box can be handed straight to the squad.
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Who We Manufacture For
- Activewear and athleisure brands launching or extending a line.
- Sports clubs, academies, and semi-professional teams ordering full kits.
- Schools, colleges, and university programs.
- Gyms, CrossFit boxes, martial arts academies, and boutique studios.
- Run clubs, cycling clubs, and race organizers.
- Wholesalers, distributors, and team dealers stocking for onward sale.
- Uniform suppliers and promotional companies adding sportswear to a catalogue.
- Corporate teams and event organizers running branded kit programs.
- Ecommerce sellers who need repeatable reorders rather than one drop.
Why Brands and Clubs Stay With Us
A team that knows the category
Our pattern and design staff work in performance fabric daily, so a brief for a cycling jersey does not get built like a t-shirt. You will be told at the quote stage if something in your spec will not survive the sport.
Priced for real margin
Per-piece costs drop at 100, 300, and 500 units per style. We quote landed cost before you commit, so you are not surprised by freight and duty after the invoice.
Low minimums
35 pieces per style, low enough to test a design on one squad or one drop before funding a season.
Dependable turnaround
Samples in 15 to 20 business days, bulk in 20 to 25 after approval. If a date is going to slip, you hear it from us before you hear it from your customer.
One supplier for the whole kit
Jersey, shorts, socks, warm ups, a jacket, and a bag were produced together and shipped in one carton, matched to the same Pantone reference.
Records kept for the reorder
Patterns, print files, and dye recipes stay on file, so a mid-season top-up matches the original run instead of drifting a shade.
