Custom Gym Wear Manufacturer for Gyms & Fitness Studios
- Est. 2005 · Sialkot, Pakistan
- MOQ 20–25 pcs per design · no limit for brands
- Free 24h digital mockup
- Sample 5–7 days, credited on bulk
- Bulk 15–25 business days · express 7–12
- DHL/FedEx/UPS 5–10 days
- 🛡️ Free remake within 3 days
Which gyms and studios this page is written for
ZipaSports manufactures custom gym wear for independent gyms, CrossFit and functional-fitness boxes, yoga and pilates studios, boutique strength studios and multi-site fitness chains, from its factory in Sialkot, Pakistan. The order pattern is the same whichever type you are: a small run of member merchandise carrying your logo, a coach or front-desk uniform, and a restock a few months later once you know what sold.
A gym is not a sportswear brand, and the ordering rules reflect that. You do not need a tech pack, a designer or a warehouse. You need a logo file, a size breakdown and a delivery address. The in-house studio builds the mockup from the logo, the factory holds the print files after the first run, and the second order is a WhatsApp message with new quantities.
Three order types come through this page: member merchandise sold or gifted at the front desk, staff kit worn on the floor, and studio-branded activewear lines that some yoga and pilates studios run as a retail rail. Each is covered below with the fabric, decoration and quantity rules that apply to it.
What a gym or studio actually orders
The garments a gym orders split into a retail set that members buy and a floor set that staff wear. The table gives the fabric and GSM options we normally quote for each, with the product page to read for cuts and colours.
| Garment | Typical buyer | Fabric and GSM options | Product page |
|---|---|---|---|
| Leggings, biker shorts | Members, yoga and pilates retail rail | Nylon-spandex or polyester-spandex 4-way stretch, 240–300 GSM, 12–20% elastane | Leggings & shorts |
| Sports bras, crop tops | Members, studio line | Nylon-spandex 240–300 GSM; seamless circular knit 180–260 GSM | Sports bras & seamless |
| Tees, tanks, muscle vests | Members and coaches | Polyester interlock 140–180 GSM with moisture-wicking finish; poly-cotton for a heavier hand | Gym tops |
| Training shorts | Members, CrossFit box drops | Polyester interlock or microfibre 140–180 GSM | Leggings & shorts |
| Hoodies, joggers, quarter-zips | Members, coach winter kit | Cotton-polyester fleece 280–350 GSM; performance poly fleece 240–300 GSM | Hoodies & jackets |
| Compression and yoga sets | Studio retail line | Polyester-spandex 240–300 GSM, squat-proof | Compression & yoga |
| Caps, socks, gym bags | Front-desk add-ons | Embroidered caps; sublimated socks; 600D polyester or 420D nylon bags | Gym bags |
Every row is available with the gym's own woven neck label, so nothing on the rail says ZipaSports. The full fitnesswear range is at fitnesswear.
Sublimation, embroidery or DTF: which one for a gym logo?
For most gym merchandise the choice is between three decoration methods, and the right one depends on the fabric and how big the graphic is. All three are done in-house at ZipaSports, so a single order can mix them across garments.
| Method | Works on | Use it for | Notes for gyms |
|---|---|---|---|
| Dye sublimation | Polyester and polyester-spandex | All-over prints, colour-blocked leggings, full-colour tees and shorts | Ink bonds into the fibre so it will not crack or peel; not for cotton-rich fleece |
| Embroidery | Fleece, piqué, caps, bags | Chest logo on hoodies, coach polos, cap fronts | Stitched crest reads as staff uniform; keep it under the size of a palm on stretch fabric |
| DTF transfer | Cotton, poly-cotton, polyester | Box logos and wordmarks on tees and hoodies, small runs with several colourways | Full-colour artwork with no set-up per colour; suits 20–25 piece drops |
| Screen print and puff print | Cotton-blend tees and fleece | One- or two-colour back prints, raised puff wordmarks | Suits one design repeated across a larger hoodie run |
A typical CrossFit box order pairs a DTF or screen-printed tee with an embroidered hoodie and sublimated shorts. A yoga studio more often wants sublimated or solid-dye leggings with a small heat-transfer logo at the hip and an embroidered crop hoodie. Read sublimation vs DTF vs embroidery for the durability comparison.
The first run: 20–25 pieces per design, sizes mixed as you need
The minimum order at ZipaSports is 20–25 pieces per design, sizes mixed within that number, and lower quantities are possible on request for a gym testing its first drop. If the gym runs its merchandise as a registered activewear brand, there is no MOQ limit at all.
In practice a first gym run looks like this: one tee design in 25 pieces split across S to 2XL, one hoodie in 25 pieces, and one leggings design in 20 pieces split across XS to XL. Women's cuts run XS–4XL and men's XS–5XL, and a design can be made in both cuts within the same run. Youth sizes are available for kids' classes and family memberships.
Many gyms pre-sell the drop to members before confirming the size breakdown with us, which removes the guesswork. Send us the mockup approval first, collect member orders for a week or two, then confirm quantities. Coach kit is normally ordered in the same consignment, often with the coach's name or role heat-pressed on the back, which is included in the decoration rather than treated as a separate design.
Private label: your studio's name on the neck, not ours
Every garment ZipaSports makes for a gym or studio can carry the studio's own branding inside and out. That means a woven neck label with your logo, a printed size tag, a care label in the wording your country requires, a hang tag for the retail rail, and a branded polybag so pieces arrive ready to sell. Details are on the labels, tags and packaging page.
Private label matters more for studios than for a box selling a tee at the desk. A yoga or pilates studio that puts its own leggings on a rail is, in effect, a small activewear brand, and members judge the garment by the label. The private label page covers the full branding menu; the short version is that nothing on the piece identifies the factory.
Label artwork is set up once and kept on file, so a restock uses the same woven label without re-approval. If the studio later wants to sell online as a brand in its own right, the same files carry over and the MOQ limit no longer applies.
Reorder cadence: drops, restocks and how we keep your files
Gyms reorder in one of two rhythms, and the factory holds the artwork, Pantone references, size specification and label files after the first run so that either can be repeated exactly.
| Model | How it runs | What you send for the reorder | Typical timing |
|---|---|---|---|
| Seasonal drop | A new colourway or graphic two to four times a year, pre-sold to members | New colour or artwork, size breakdown | Mockup 24h, then 15–25 business days production |
| Core restock | Same tee, hoodie and leggings kept in stock at the desk all year | Order reference and quantities only | 15–25 business days, express 7–12 days if the rail is empty |
| Staff top-up | New coaches joining, replacement uniform | Names or roles and sizes | Lower quantities on request for established gyms |
| Event or challenge tee | One-off run for a competition, open day or eight-week challenge | Event artwork and a date | Express production 7–12 days plus 5–10 days courier |
Because sublimation and DTF artwork is digital, a colourway change on a restock does not need new screens or set-up. Approved colours are matched to the earlier run so a hoodie bought in January and one bought in September sit together on the rail.
Lead times and shipping to the UK, USA, Canada, Australia and Europe
From logo to garments at the front desk, a standard gym order takes the following path. Everything runs in-house in Sialkot, Pakistan, so the dates below are production dates, not a chain of subcontractors.
- Free digital mockup within 24 hours of receiving your logo and garment list, with unlimited revisions before approval.
- Optional physical sample in 5–7 days, charged at sample cost and credited against the bulk order. Most gyms sample the leggings and skip sampling the tee.
- Bulk production in 15–25 business days after approval; express production in 7–12 days at additional cost.
- Courier by DHL, FedEx or UPS in 5–10 days to the UK, USA, Canada, Australia and Europe, with tracking sent to you. Sea freight in 3–6 weeks is only worth it for large multi-site orders.
Orders ship in one consignment to the gym's address, packed by garment and size so the desk can shelve it without re-sorting. Export documents (commercial invoice, packing list, certificate of origin) are supplied; import VAT or duty in the destination country is payable by the importer unless otherwise agreed. Country detail is on the UK, USA, Canada, Australia and EuropeIrelandNew ZealandUAESaudi Arabia pages and the shipping policy.
What you need to send us, and the Quality Guarantee
A gym order starts with this list; the ZipaSports studio does the drawing.
| Item | Format | Needed for |
|---|---|---|
| Gym or studio logo | Vector (AI, EPS, PDF) preferred; a clean PNG will do for a mockup | Mockup and embroidery digitising |
| Garment list | Which pieces, which cuts (men's, women's, unisex, youth) | Quote and mockup |
| Colours | Pantone references, or a photo of your interior branding | Sublimation and thread matching |
| Size breakdown | Quantity per size per design, 20–25 pieces per design minimum | Cutting plan |
| Staff names or roles | Spreadsheet, one line per garment | Coach kit personalisation |
| Label wording | Brand name, care text, country of sale | Woven labels and size tags |
| Deadline and address | Launch date, delivery address, contact for the courier | Production scheduling and shipping |
Quality Guarantee: if any garment arrives with a manufacturing defect, we remake it free of charge — the remake goes into production within 3 days of your report. Send photos and the order reference within 7 days of delivery; we confirm within 24 hours. Print faults, stitching faults, wrong sizes against the approved specification and wrong quantities are covered; minor dye-lot shade and small measurement tolerance are not. Made-to-order garments with your label cannot be returned for change of mind. Full wording is at quality guarantee.
Frequently Asked Questions
Who makes custom gym wear for a small independent gym or CrossFit box?
ZipaSports in Sialkot, Pakistan manufactures custom gym wear for independent gyms and CrossFit boxes from 20–25 pieces per design, with the gym's logo and own neck label. The mockup is free within 24 hours, and tees, hoodies, shorts and leggings can be mixed in one order.
Can our gym order just 25 tees and 25 hoodies to start?
Yes — the minimum order is 20–25 pieces per design with sizes mixed inside that number, so 25 tees and 25 hoodies in your own size split is a normal first order. Lower quantities are possible on request if you want to test a single design first.
Do we need to be a registered brand to get our own labels?
No — any gym or studio can have woven neck labels, printed size tags, hang tags and branded polybags on a 20–25 piece run without being a registered brand. If you do operate as a registered activewear brand, the MOQ limit is removed altogether.
Can our yoga studio sell leggings under its own name?
Yes — a yoga studio can sell leggings under its own name, made in nylon-spandex or polyester-spandex 4-way stretch at 240–300 GSM with 12–20% elastane and carrying your woven label and hang tag. Solid-dye or sublimated colourways are both available, and reorders match the approved colour.
Which print method lasts longest on gym tees that are washed constantly?
Sublimation on polyester lasts longest because the dye bonds into the fibre and cannot crack or peel. On cotton-blend tees, DTF or screen print is used; embroidery is the most durable option for hoodies, polos and caps.
Can coaches have their names or 'COACH' on the back?
Yes — coach names, roles and member numbers are added by sublimation or heat transfer as part of the decoration, not as a separate design, so five coaches with five different names still count within one design's 20–25 pieces.
How long before our launch date should we order?
A gym order takes roughly four to seven weeks from logo to front desk: a 24-hour mockup, 15–25 business days of production and 5–10 days of courier. Express production in 7–12 days shortens that to about three weeks if a date is fixed.
Can we reorder the same hoodie in a new colour next quarter?
Yes — a hoodie can be reordered in a new colour, because artwork, label files and the approved size specification are kept on file and a restock only needs the new quantities. Sublimation and DTF artwork is digital, so a colour change involves no new set-up.
What happens if a batch arrives with a print fault or wrong sizes?
A print fault or a wrong size against the approved specification is a manufacturing defect under the ZipaSports Quality Guarantee, and the affected pieces are remade free of charge with the remake in production within 3 days of your report. Send photos and the order reference within 7 days of delivery.
Do we pay import duty on gym wear shipped to the UK or USA?
Import VAT or duty in the destination country is payable by the importer on arrival unless otherwise agreed; the courier handles clearance and we provide the commercial invoice, packing list and certificate of origin. Full detail is on the shipping policy page.