Activewear Tech Pack Checklist: What Your Factory Needs

Short answer: a factory-ready activewear tech pack should define the product visually and numerically: technical drawings, bill of materials, fabric performance, construction, measurements and tolerances, colors, branding, labels, packaging, testing and revision history. It does not need to be perfect before the first conversation, but all approved details must be consistent before sampling and bulk production.

First choose the right sourcing route. A tech pack is for Full Custom Manufacturing, which starts from 200 pieces per color and style. Ready Styles do not require a tech pack because they are selected privately from the current Excel catalogue and start from 50 pieces per style.

If you only want to know what to send in the first message, use the shorter activewear quotation checklist. This guide explains how to build the technical document that follows.

The 12-part activewear tech pack checklist

One PDF or spreadsheet can contain all twelve parts. What matters is that the information is readable, measurable and controlled under one revision number.

1. Cover page and document control

Give the factory an unambiguous identity for the product and file:

• brand or project name;
• unique style code and working style name;
• product category and intended gender or fit block;
• season or delivery window, if relevant;
• sample size and planned size range;
• measurement unit — centimetres or inches, never an unexplained mixture;
• document version, issue date and responsible contact;
• confidentiality note or NDA reference, if applicable.

Place the style code, version and page number on every page. A filename such as LS101_Tech-Pack_V03_2026-08-10.pdf is far safer than final-new-latest.pdf.

2. Technical flat drawings

Provide clean front and back flats. Add inside views and enlarged callouts where a factory cannot see the construction from the outside. Show seams, panels, pockets, openings, closures, elastic, drawcords and hardware.

Reference photography can communicate mood, but it is not a technical drawing. If a photo belongs to another brand, use it only to explain a specific feature and state what should change. Do not ask a supplier to copy another brand’s protected product or artwork.

For activewear, details commonly missed in drawings include:

• gusset shape and seam position on leggings;
• internal bra construction, cup pockets and underband elastic;
• waistband height, internal elastic and drawcord route;
• pocket opening, depth and phone-retention construction;
• reflective placements on running garments;
• bonded, taped, flatlocked or coverstitched areas;
• lining and clean-finish construction on swimwear.

3. Bill of materials (BOM)

The BOM lists every material and component needed to build one finished garment. Give each item a reference number that also appears on the drawings.

Do not write only “same as reference.” The factory needs either an approved physical reference or a specification it can source and reproduce.

4. Fabric and performance specification

Activewear cost and performance depend heavily on the fabric, so “nylon spandex” is not enough. Define what you know and label unknown items for factory recommendation.

Include:

• fiber composition and permitted tolerance, if already fixed;
• fabric construction, such as interlock, jersey, rib, mesh, woven or seamless knit;
• target weight in GSM and an acceptable range;
• stretch direction and target stretch/recovery behavior;
• hand feel, compression and opacity expectations;
• moisture-management, quick-dry, brushing, peaching, anti-pilling or water-repellent finish;
• target color, lab-dip process and approval reference;
• any recycled-content, chemical or material certification requirement that must be supported by current documents.

For seamless development, attach the route-specific fields in the seamless vs cut-and-sew activewear manufacturing guide: machine/program and size groups for circular seamless, the designated flat-bed route where applicable, or panel/pattern/seam controls for cut-and-sew.

Pantone references are useful for communicating a target, but color appearance changes across fibers, finishes and light sources. The approved lab dip or physical swatch should become the production control, not the Pantone number alone.

Use the activewear color approval, Pantone and lab-dip checklist to specify the physical target, viewing conditions, color-difference method, retained reference and bulk shade-lot release without inventing one universal Delta E tolerance.

For sweat-related claims, use the activewear moisture-wicking and quick-dry test guide to specify liquid transport, drying, water-vapour or air-flow evidence without treating “wicking,” “quick-dry,” “breathable” and “cooling” as interchangeable.

For odor-control or antimicrobial language, use the activewear anti-odor testing guide to define the exact mechanism, method, odor chemical or organism, control, finish, after-care state and destination-market claim boundary. An ingredient name or antibacterial percentage is not a complete public claim.

For leggings, shorts and other high-extension zones, use the activewear opacity and squat-proof testing guide to specify the exact fabric/color, working extension, background, lighting, fit, movements, observation and pass rule. GSM, elastane percentage, UPF and an unstretched swatch are not substitutes.

If you do not know the right GSM or stretch level, describe the activity, climate, coverage, support and target hand feel. The factory can then recommend options for sampling instead of guessing from a generic fabric name.

5. Construction and workmanship

Use annotated callouts or a construction table to define how components are assembled. Specify seam and stitch type where it affects performance or appearance, and show seam allowance or finished width for critical details.

Activewear may use overlock, coverstitch, flatlock, zigzag, bartack, bonding or seam tape in different areas. The correct choice depends on fabric stretch, body contact, support, equipment and price. If you are unsure, state the result you need — low bulk, skin comfort, reinforcement, water resistance or a clean bonded appearance — and ask the factory to propose a method.

Also define:

• stitch color and whether it should match or contrast;
• reinforcement at pockets, strap joins, drawcord exits and stress points;
• raw-edge, turned, bound or bonded finishing;
• elastic insertion, tension and finished width;
• zipper length and opening direction;
• pattern matching or placement rules for prints.

6. Points of measure, tolerances and grading

A measurement chart should tell the sample room exactly where and how to measure the garment. Use numbered points of measure (POMs) that match a measurement diagram.

For each POM, include:

• measurement name and illustrated location;
• sample/base-size specification;
• tolerance for sample and bulk inspection;
• grade rule or measurements for every ordered size;
• whether the measurement is taken relaxed, extended, along a curve or straight;
• any elastic-extension or strap-adjustment condition.

Do not give only body measurements unless the factory is explicitly responsible for developing the finished-garment specification. Activewear ease changes with fabric power, compression, stretch and intended fit. The finished measurement and approved fit sample together become the production reference.

Use the activewear size grading and fit approval checklist to separate body measurements, finished-garment POMs, grade increments and bulk tolerances, then control the base fit and size-set approvals.

If the product brief uses “compression,” “zonal,” “graduated” or a wearer-benefit claim, attach the compression activewear testing protocol rather than leaving one undefined adjective in the measurement chart.

7. Colorways and print information

Create one colorway page showing every component color for each ordered option: shell, lining, mesh, thread, elastic, zipper, logo, label and hardware. Assign a simple colorway code and use it on the order breakdown.

For prints, provide a repeat tile or placement artwork at production scale, file type, dimensions, colors and intended process. State whether the artwork is engineered to a garment panel or repeated across the fabric. Approve a strike-off before bulk printing when color, scale or registration is critical.

8. Logo, artwork and branding placement

Supply vector artwork where possible and identify:

• final width and height;
• distance from two stable reference points or seams;
• color and finish;
• application method;
• orientation on left/right garments;
• minimum durability or wash expectation;
• approval sample required before bulk.

“Logo on the hip” is open to interpretation. “60 mm wide, centered 35 mm below the top waistband seam and 45 mm from the left side seam” can be checked.

9. Labels and market information

List every label and the exact information to print. Fiber content, care instructions, country of origin, responsible business information, language and other marking rules depend on the destination market and product. Confirm the current legal requirements with a qualified compliance adviser for every market; the factory should not be asked to invent mandatory wording.

Make the tech pack clear about label material, dimensions, fold, attachment position, stitch method and orientation. Attach final artwork rather than copying text between email threads.

10. Packaging and assortment

Packaging affects cost, compliance and warehouse handling. Define the folding method, individual packaging, hangtag, barcode or SKU label, size sticker, carton markings, carton limits and packing ratio.

If the buyer, retailer or fulfillment warehouse has a manual, attach the current version and identify which rules apply. Packaging should be reviewed before the pre-production sample because label and barcode errors can block otherwise acceptable goods.

Use the custom labels, logos and packaging guide to turn these sections into component-level artwork, label-copy, barcode, approval, setup and MOQ instructions.

11. Testing and quality requirements

Write performance expectations that match the product’s real use. Possible checks include:

• dimensional stability and appearance after washing;
• colorfastness to washing, rubbing and perspiration;
• stretch recovery and seam extension;
• pilling and abrasion resistance;
• opacity under stretch for leggings;
• support and strap security for sports bras;
• print, logo and bonded-seam durability;
• chlorine, saltwater and sunscreen exposure for swimwear — define the exact methods, conditions and pass criteria using the swimwear colorfastness test guide;
• water resistance or repellency for relevant outerwear;
• needle, sharp-point and general workmanship checks.

For wash-related specifications, use the activewear shrinkage and dimensional-stability wash test guide to name the measurement points, ISO/AATCC route, wash and drying procedure, cycles, conditioning, sign convention and separate limits for linear change, spirality, appearance and fit.

For color performance, use the activewear colorfastness test guide to keep washing color change/staining, dry and wet rubbing, perspiration and light as separate methods, results and acceptance fields.

Name the required test method, laboratory, pass level and test stage when your retailer or market requires one. Do not add a standard number copied from another product unless it actually applies to the material, market and claim.

For chemical requirements, attach the activewear chemical-compliance checklist and identify the destination law, buyer RSL, manufacturing MRSL, exact BOM/components, certificate scope, sample matrix, report/declaration format and claim wording. “REACH compliant” or a certification logo alone is not a complete testing specification.

For a sports bra, attach the 26-field fit, breast-motion, strap/underband-pressure and support-durability protocol. A brand’s low/medium/high label is not a universal laboratory class and cannot replace the protocol.

For high-strain construction, use the activewear seam strength and stretch test checklist to define the seam class, stitch, thread, needle, density, allowance, test direction, load or extension and prohibited failure modes. A fabric-burst result does not approve a sewn seam, and a straight woven-seam method does not automatically validate a curved knit crotch.

12. Sample comments, approvals and revision history

Keep sample feedback inside a controlled comment sheet. For every issue, include a photo or POM reference, the current result, the requested change and the approval status. Consolidate comments into one dated response rather than sending conflicting instructions across WhatsApp, email and shared documents.

Maintain a revision table with:

Never overwrite an approved version without recording the change. The final tech pack, approved pre-production sample and confirmed purchase order must agree before bulk cutting. Use the 24-field activewear purchase order checklist to lock the commercial authorization, color-size matrix, trade term, delivery events, quality plan and release status without duplicating the product specification.

Common tech pack problems that delay a quote

Factories lose time when they have to decide which instruction is real. Check for these problems before sending:

1. Reference images with no change notes. Mark exactly which feature is relevant and what is different.
2. Conflicting pages. The drawing, BOM, measurement chart and colorway must describe the same version.
3. No base size or tolerance. A number without a size, unit and measuring method cannot control fit.
4. Generic fabric language. Composition alone does not define weight, construction, stretch, recovery or finish.
5. Unplaced branding. Give dimensions and measurable placement, not “small logo here.”
6. Missing order breakdown. MOQ and price are evaluated per color and style, not only against a total collection quantity.
7. Uncontrolled comments. One dated master file should replace scattered messages after every approved revision.
8. Claims without a test plan. Words such as recycled, UV-protective, waterproof or antibacterial may require evidence and market-specific substantiation.

If your tech pack is not finished yet

You can still begin a factory conversation. Send a concise development brief so feasibility can be reviewed before you pay a designer to document an unsuitable construction.

Copy-and-send custom development brief

Hi Jerry, I want to develop a custom ____. Target quantity: ____ pieces per color and style. Target market: ____. Intended activity and fit: ____. My starting material is a [draft tech pack / reference image / physical sample / sketch]. The main changes or required features are ____. Preferred sample or launch timing: ____. Please advise which specifications are still needed for feasibility and quotation.

The standard Full Custom starting point is 200 pieces per color and style; special fabrics, trims, molds, seamless constructions or other processes may require a higher minimum. Start a Full Custom enquiry when you are ready for a review.

What happens after the factory receives it

The factory first checks whether the drawings, materials, construction, measurements, order quantity and performance requirements agree. Open questions are resolved before the sample scope and quotation are finalized. The approved specification then moves through development, fit review and pre-production approval; see the activewear sampling process for the role of each sample.

For an OEM program, your tech pack is the main manufacturing instruction. For an ODM program, the factory may begin from an existing design base and document the approved changes. The OEM vs ODM activewear guide explains that decision.

The best tech pack is not the longest one. It is the shortest controlled document that removes ambiguity about the product, the approved sample and the order.