How To Start a Fitness Clothing Line: 7 Steps for Making Your Own Activewear 

The demand for fitness apparel has skyrocketed, transforming activewear from gym essentials into everyday fashion.

Today, almost every popular brand has created its own line of sportswear, cashing in on the growing demand for stylish, functional activewear that seamlessly blends performance and fashion.

From luxury labels like Gucci and Michael Kors to mainstream giants like Nike and Adidas, brands are capitalizing on the athleisure boom—but they’re not the only ones.

Content creators and influencers are also launching their own athletic clothing lines, leveraging their online communities to sell exclusive, custom-designed activewear.

And with the rise of print-on-demand platforms, starting your own fitness clothing line has never been more accessible. 

In this guide, we'll walk you through the steps to design, market, and sell your own custom athletic wear without the need for large upfront investments or inventory management. 

Whether you're a content creator looking to monetize your audience or an entrepreneur eager to break into the booming sportswear market, this step-by-step guide will help you launch a successful gym clothing brand.

How Profitable Can Selling Athletic Wear Online Be?

Athletic wear has surged in popularity due to the rise of athleisure—a fusion of fitness and fashion that blends style, comfort, and performance.

More people than ever are wearing activewear not just for workouts but for everyday activities, from running errands to casual outings.

With a growing emphasis on health, wellness, and sustainability, consumers are seeking high-quality, customizable sportswear that fits their personal style and lifestyle.

This increasing demand has fueled rapid growth in the sportswear customization service market, which was valued at $182.01 billion in 2023 and is projected to reach $305.67 billion by 2031, according to recent data. 

The industry’s expansion presents a prime opportunity for content creators, especially those in fitness and fashion, to design and sell their own branded athletic wear.

Why Content Creators Should Get Into Custom Activewear

For fitness creators, launching a custom athletic wear line allows them to monetize their brand in an organic way.

Whether it’s high-performance leggings, moisture-wicking tops, or gym accessories, offering exclusive workout apparel strengthens community engagement and builds brand loyalty.

Fans who follow fitness influencers for inspiration are likely to invest in apparel designed by them.

Fashion creators can also benefit from the athleisure movement, which is now a dominant trend in both casualwear and luxury fashion.

By curating stylish and functional pieces, creators can appeal to their audience’s demand for unique, high-quality sportswear that reflects their personal brand.

Profit Margins and Earning Potential

Selling custom athletic wear online can be highly profitable, with profit margins ranging from 30% to 60%, depending on several factors:

• Pricing Strategy: Premium activewear (like compression leggings or high-performance gym wear) can yield higher margins, while more budget-friendly options may generate higher sales volume.
• Target Market: Niche-focused products (such as sustainable activewear or sport-specific clothing) can command premium pricing and strong brand loyalty.
• Volume vs. Margin: Selling a smaller number of high-end items at a higher price can be as profitable as selling large quantities of budget-friendly activewear.

Major brands like Gymshark and Lululemon have built multi-million-dollar businesses by focusing on premium pricing, strong customer loyalty, and strategic social media marketing—a tactic that content creators can replicate on a smaller scale.

With print-on-demand services like Fourthwall, Printful, and Printify, creators can easily launch an athletic wear brand without upfront inventory costs, making it an accessible and low-risk business venture.

As demand for personalized fitness fashion continues to rise, now is the perfect time for creators to tap into this thriving market and turn their audience into customers.

7 Steps to Make and Sell Athletic Wear Online

Now that you understand the profitability of athletic wear and the types of garments to create, let’s break down the steps involved in building and selling an athletic wear business online. Below are seven essential steps to help you design, sell, and market your own online fitness apparel.

Step 1: Research the Market

Before launching your workout clothing brand, it’s crucial to analyze the clothing market to identify trending styles, competitor offerings, and consumer demands.

Some insights to consider:

• 36% of active gym members are Millennials, a generation that prioritizes stylish, performance-driven gym apparel.
• 42% of gym memberships come from boutique fitness studios, suggesting that customers are willing to invest in high-quality, customized fitness apparel that aligns with their preferred workout routines.
• The rise of athleisure and streetwear has increased demand for versatile gym clothing that transitions from workouts to casual wear.
• Eco-conscious consumers are looking for sustainable activewear made from recycled fabrics and organic materials, making this a niche worth exploring.

Use research tools like Google Trends, Instagram, and competitor analysis to determine what’s in demand and find a unique angle for your fitness brand.

Step 2: Create Your Designs

Your designs will set your gym clothing brand apart from competitors. Whether you focus on minimalist streetwear-inspired gym apparel or performance-driven sports clothing, your brand identity should reflect your target audience's preferences.

• Design Tools: Platforms like Adobe Illustrator, Canva, or Procreate can help bring your vision to life.
• Functionality Matters: Think beyond aesthetics and incorporate breathable fabrics, moisture-wicking properties, and ergonomic fits into your designs.
• Customization: If using print-on-demand services like Fourthwall, ensure your designs are optimized for printing on gym apparel.

If you're not a designer, consider hiring a freelance graphic artist who specializes in fitness clothing design.

Step 3: Choose a Print-on-Demand Platform

A print-on-demand (POD) service is one of the easiest ways to launch a fitness clothing brand without dealing with inventory or large upfront costs. POD platforms handle printing, fulfillment, and shipping for you, allowing you to focus on design and marketing.

Popular POD platforms that offer gym apparel include:

• Fourthwall: Offers high-quality sportswear, including t-shirts, hoodies, leggings, sports bras, and shorts with seamless ecommerce platform integration.
• Printful: Specializes in premium gym clothing, including performance shirts and activewear.
• Teespring: A budget-friendly option for simple fitness apparel designs.

Choose a platform that aligns with your brand’s vision, product selection, and pricing model.

Step 4: Set Up an Online Store

Your online store is the face of your clothing business, so it needs to be visually appealing, user-friendly, and mobile-optimized.

Key steps to setting up your store:

• Select an ecommerce platform: Options like Fourthwall, Shopify, Etsy, or WooCommerce allow you to sell custom sportswear online.
• Customize your storefront: Create an eye-catching brand identity with high-quality images, compelling product descriptions, and a seamless checkout experience.
• Categorize your products: Organize your clothing items into clear collections (e.g., leggings, sports bras, workout hoodies).

Your goal is to make shopping intuitive and engaging for customers to encourage more sales.

Step 5: Price Your Athletic Wear

Setting the right price is essential for profitability. Consider factors like:

• Production Costs: Factor in POD service fees, printing costs, and shipping rates.
• Market Research: Compare your pricing with competitors in the fitness clothing market.
• Profit Margins: Most gym clothing brands aim for a 30%-60% margin on workout clothing.

For premium gym apparel, a higher price point is acceptable if you emphasize quality, performance, and unique designs.

Step 6: Market Your Fitness Apparel Brand

Once your store is live, it's time to build brand awareness and attract customers.

Effective marketing strategies for fitness brands:

• Social Media Marketing: Use platforms like Instagram, TikTok, and YouTube to showcase your gym clothing in action.
• Influencer Collaborations: Partner with fitness influencers who align with your brand.
• Content Marketing: Create fitness tutorials, styling guides, and workout tips featuring your clothing items.
• Paid Advertising: Invest in Facebook Ads, Google Ads, and Instagram promotions to drive traffic to your online store.
• Email Marketing: Build an email list and send out promotions, exclusive drops, and new product launches.

Your marketing should communicate why your sportswear stands out and how it enhances performance, comfort, or style.

Step 7: Manage Orders & Customer Service

With a print-on-demand model, order fulfillment and shipping are handled by your POD partner, but customer service remains your responsibility.

How to ensure customer satisfaction:

• Track orders: Stay updated on shipping timelines and fulfillment.
• Offer clear return/exchange policies: Make it easy for customers to understand your refund process.
• Engage with customers: Answer questions via email, live chat, or social media to build trust.
• Monitor reviews: Encourage customer feedback and showcase positive testimonials on your site.

Providing top-notch customer support will help establish your clothing line as a trusted brand in the sportswear market.

Best Athletic Garments to Create

Launching an activewear line means selecting the right garments that cater to your audience’s needs and lifestyle. 

With Fourthwall’s extensive product catalog, creators can design high-quality, customizable athletic apparel that aligns with their brand. 

Below are some of the best options to consider:

1. Performance Shirts

Shirts are an essential clothing item in any gym clothing brand, catering to both high-performance athletes and those who prefer stylish streetwear-inspired sports clothing.

From moisture-wicking gym shirts for high-intensity workouts to casual athleisure tops, custom fitness apparel offers versatility for your target market.

2. Sports Bras 

A staple in women’s gym apparel, sports bras are a must-have for any fitness brand looking to cater to yoga, running, and strength training audiences.

Offering high-support, breathable sports bras can make your gym clothing brand more inclusive while also tapping into the growing demand for yoga pants and workout clothing designed for both fashion and functionality.

3. Gym Shorts 

Gym shorts are a must-have in any gym clothing business, providing breathability, mobility, and sweat-wicking technology.

With demand for sportswear-inspired streetwear on the rise, custom mesh shorts can appeal to both athletes and those who prefer relaxed workout clothing that transitions from the gym to everyday wear.

4. Hoodies 

Hoodies are an essential clothing item for gym-goers who want stylish, functional layering options.

Whether it’s a breathable hoodie for post-workout wear or a cozy, oversized fit for lounging, hoodies are a versatile addition to any gym clothing line.

5. Athletic Hats 

For fitness brands looking to expand beyond gym clothing, caps, and accessories can be a great business plan strategy.

Moisture-wicking athletic hats are a great add-on for runners, cyclists, and gym-goers, making them a smart ecommerce platform addition to complement your sportswear collection.

6. Leggings & Yoga Pants

No fitness brand is complete without leggings and yoga pants.

These best-selling clothing items are popular in both gym apparel and athleisure fashion, making them a profitable addition to your clothing line.

Whether you’re targeting yoga lovers, weightlifters, or those who prefer sports clothing that blends comfort and style, leggings offer a high-margin business opportunity in the fitness clothing market.

Launch Your Athletic Apparel Brand with Fourthwall

Ready to start your own fitness clothing line? 

Fourthwall provides everything you need to design, sell, and grow your athletic apparel business with zero upfront costs and no inventory management required. 

Whether you're a content creator, influencer, or entrepreneur, Fourthwall’s all-in-one platform makes launching a custom activewear brand easier than ever.

Why Choose Fourthwall?

• Customizable Storefronts: Create a sleek, branded online store with easy-to-use design tools tailored to your style.
• Premium Athletic Clothing: Sell high-quality gym apparel, yoga pants, sportswear, and streetwear-inspired fitness clothing with top-tier printing and embroidery options.
• No Upfront Costs or Inventory Management: Focus on building your brand while Fourthwall handles production, fulfillment, and shipping.
• Built-In Marketing Tools: Track sales, create discounts, and leverage SEO-friendly product pages to boost visibility.
• Seamless Payment Integration: Accept Apple Pay, PayPal, credit cards, and other secure payment methods.
• Direct Fan Engagement: Offer exclusive memberships, limited-edition drops, and merch bundles to connect with your audience.

Signing up is quick and easy! Simply create a Fourthwall account, upload your fitness apparel designs, set your pricing, and launch your clothing business in minutes. 

With Fourthwall’s streamlined tools and hands-free fulfillment, you can start selling activewear while focusing on what you do best—growing your brand and engaging your audience.

Join Fourthwall and start your athletic wear brand today!

Frequently Asked Questions

How to Start an Athleisure Clothing Line?

Launching an athleisure clothing line begins with selecting a target market and designing stylish yet functional athletic clothing that blends performance with everyday wear.

Whether you focus on yoga pants, gym sets, or streetwear-inspired activewear, it’s crucial to work with reliable clothing manufacturers or print-on-demand services to produce high-quality garments.

Setting up an online store through platforms like Fourthwall or Shopify allows you to reach a broad audience, while social media marketing and influencer collaborations can help grow your brand.

A solid business plan that outlines pricing, branding, and product selection will set the foundation for long-term success in the competitive apparel business.

How Do I Start a Fitness Apparel Brand?

To start a fitness apparel brand, focus on creating high-quality gym clothing that meets the needs of your target audience, whether it’s gym-goers, athletes, or casual fitness enthusiasts.

Work with clothing manufacturers or print-on-demand platforms to source durable fabrics that offer comfort, breathability, and flexibility.

Building a strong brand identity through compelling social media content, influencer partnerships, and SEO-driven marketing is essential for visibility.

Selling through ecommerce platforms like Fourthwall, Etsy, or Shopify ensures a seamless customer experience, while offering products like sneakers, yoga pants, and gym sets can help diversify your clothing business.

How to Start an Activewear Clothing Line?

Starting an activewear clothing line requires a clear business plan and a deep understanding of the athletic clothing market.

Begin by identifying your target market—whether it’s high-performance sportswear, athleisure, or eco-friendly gym apparel.

Choose a manufacturing partner or print-on-demand service to produce high-quality, moisture-wicking fabrics that enhance performance.

Setting up an ecommerce store with Fourthwall, Shopify, or WooCommerce allows for easy scalability, while social media marketing helps build brand awareness.

Collaborating with fitness influencers, running ads, and leveraging SEO-driven content can drive traffic to your store and increase sales, positioning your brand for long-term success in the booming clothing business.