Best Activewear Fabrics for Custom Printing

Why Fabric Choice Matters for Custom Activewear

When you’re creating custom activewear for your gym, studio, or fitness brand, the fabric is just as important as the design. The wrong fabric can lead to prints that crack, peel, or wash out after a few sessions. The right fabric ensures your custom gear looks sharp, feels comfortable, and performs under pressure.

At Fitprint, we work with activewear fabrics daily through our custom activewear printing service. This guide shares everything we’ve learnt about which fabrics deliver the best results for the fitness industry.

Understanding Activewear Fabric Properties

Before diving into specific fabrics, it’s worth understanding the key properties that make a fabric suitable for gym and fitness apparel.

Moisture-Wicking

This is non-negotiable for activewear. Moisture-wicking fabrics pull sweat away from the skin to the fabric’s outer surface, where it evaporates. This keeps the wearer dry and comfortable during intense training.

Stretch and Recovery

Good activewear moves with the body. Fabrics with stretch (typically from elastane or spandex content) allow full range of motion, while recovery ensures the garment returns to its original shape after stretching.

Breathability

Breathable fabrics allow air to circulate, helping regulate body temperature during exercise. Mesh panels and lighter fabric weights enhance breathability.

Durability

Gym gear takes a beating. Between heavy use, frequent washing, and exposure to sweat, the fabric needs to hold up over time without pilling, fading, or losing shape.

The Best Fabrics for Custom Activewear Printing

Polyester

Best for: Training tees, singlets, performance tops, sublimation printing

Polyester is the workhorse of the activewear world. It’s lightweight, moisture-wicking, quick-drying, and incredibly durable. Most performance activewear you see in gyms across Australia is predominantly polyester.

Printing compatibility:

• Excellent with DTF printing — the transfer bonds cleanly to polyester’s smooth surface.
• Ideal for sublimation printing, which is actually exclusive to polyester and polyester-rich blends.
• Screen printing can be challenging on 100% polyester due to dye migration (where fabric dye bleeds into the ink).

Considerations:

• Can feel less breathable than natural fibres in very hot conditions.
• Look for polyester fabrics with textured or waffle-knit construction for improved breathability.
• Recycled polyester (rPET) is increasingly popular for eco-conscious brands.

Nylon (Polyamide)

Best for: Leggings, compression wear, shorts, sports bras

Nylon is softer and silkier than polyester, with excellent stretch and a premium feel against the skin. It’s the go-to fabric for leggings, compression tights, and form-fitting activewear.

Printing compatibility:

• Works very well with DTF printing.
• The smooth surface of nylon accepts transfers cleanly.
• Heat sensitivity requires careful temperature control during pressing — an experienced printer knows exactly how to handle it.

Considerations:

• Generally more expensive than polyester.
• Can absorb more moisture than polyester, which means slightly slower drying time.
• Often blended with elastane for optimal stretch and recovery.

Spandex/Elastane Blends

Best for: Any garment requiring significant stretch — leggings, sports bras, compression tops

Spandex (also known as elastane or by the brand name Lycra) is rarely used on its own. Instead, it’s blended with polyester or nylon to add stretch and recovery. A typical activewear blend might be 80% polyester/20% elastane or 75% nylon/25% elastane.

Printing compatibility:

• The key challenge with high-stretch fabrics is ensuring the print stretches with the fabric without cracking.
• DTF printing excels here because the transfer film is inherently flexible.
• Prints should be applied while the fabric is in a relaxed (unstretched) state to avoid distortion.

Considerations:

• Higher elastane content means more stretch but can make printing more complex.
• Blends with 15-25% elastane offer the best balance of stretch and print compatibility.
• Always work with a printer experienced in performance fabrics.

Poly-Cotton Blends

Best for: Casual gym tees, hoodies, crew necks, everyday training tops

Poly-cotton blends (often 60/40 or 50/50 polyester to cotton) combine the moisture management of polyester with the soft, natural feel of cotton. They’re a popular choice for more casual gym apparel and lifestyle pieces.

Printing compatibility:

• Compatible with virtually all printing methods — DTF, screen printing, and more.
• Cotton content helps with ink absorption for screen printing.
• DTF prints adhere excellently to poly-cotton blends.

Considerations:

• Not as moisture-wicking as 100% polyester or nylon.
• Better suited for lower-intensity activities or lifestyle wear rather than high-performance training.
• Heavier than pure synthetic alternatives.

Mesh Fabrics

Best for: Panels, inserts, back sections for ventilation

Mesh fabrics are typically polyester-based with an open-weave construction that maximises airflow. They’re commonly used as panels or inserts in training tops, tank tops, and shorts rather than as the primary fabric.

Printing compatibility:

• The open weave of mesh makes direct printing challenging.
• DTF transfers can work on tighter mesh constructions but may not adhere well to very open weaves.
• Best used for unprinted sections of garments where ventilation is the priority.

Considerations:

• Pair mesh panels with solid fabric printing areas for the best of both worlds.
• Consider the mesh density — tighter mesh is more print-friendly.

Bamboo Blends

Best for: Eco-conscious activewear lines, yoga and pilates wear, recovery wear

Bamboo fabric (technically bamboo viscose or bamboo rayon) is prized for its softness, natural antibacterial properties, and sustainability credentials. It’s becoming increasingly popular in the Australian activewear market.

Printing compatibility:

• DTF printing works well on bamboo blends.
• The fabric’s softness means prints need to be equally soft and flexible to maintain comfort.
• Lower heat tolerance than polyester — requires careful press temperature management.

Considerations:

• Not as durable or moisture-wicking as synthetic alternatives.
• Best suited for lower-impact activities like yoga, pilates, and general lifestyle wear.
• Appeals to the growing eco-conscious segment of the fitness market.

Fabric Weight: Why GSM Matters

GSM (grams per square metre) indicates the weight and thickness of a fabric. For activewear, the right GSM depends on the garment type:

• 120-160 GSM: Lightweight — ideal for singlets, running tops, and warm-weather training gear.
• 160-200 GSM: Mid-weight — suits training tees, leggings, and all-round gym apparel.
• 200-280 GSM: Heavyweight — best for hoodies, crew necks, and cooler-weather layers.
• 280+ GSM: Extra heavy — track pants, heavy hoodies, and outerwear.

Lighter fabrics generally accept prints more easily and feel more comfortable with a printed design, while heavier fabrics can support larger, bolder prints.

How DTF Printing Handles Different Fabrics

One of the biggest advantages of DTF printing for activewear is its versatility across fabric types. Unlike sublimation (polyester only) or screen printing (best on cotton), DTF transfers bond to virtually any fabric.

Here’s a quick compatibility summary:

Fabric	DTF Compatibility	Notes
Polyester	Excellent	Clean adhesion, vibrant colours
Nylon	Excellent	Lower press temperature required
Spandex blends	Very good	Flexible print moves with fabric
Poly-cotton	Excellent	Ideal all-round performance
Mesh	Variable	Depends on mesh density
Bamboo blends	Good	Lower heat, softer press

Choosing the Right Fabric for Your Project

The best fabric depends on your specific needs:

• Gym training tops and singlets: Polyester or poly-cotton blends in 140-180 GSM.
• Leggings and compression wear: Nylon-elastane or polyester-elastane blends.
• Hoodies and lifestyle pieces: Poly-cotton blends in 280+ GSM.
• Competition and event wear: Lightweight polyester with moisture-wicking finish.
• Yoga and wellness wear: Bamboo blends or soft nylon-elastane.

Let Fitprint Guide Your Fabric Decision

Choosing the right fabric and printing combination doesn’t have to be guesswork. Our team works with fitness businesses across Australia daily and can recommend the ideal fabric for your custom activewear project.

Whether you’re launching a new gym merch line or outfitting your team for competition, Fitprint’s custom activewear printing service ensures your designs look incredible on the right fabrics.

Get started with your order and let’s create custom activewear that performs as hard as your members do.