What Is Sportswear Made Of? The 5 Most Dominant Fabrics
Perhaps the only silver lining of 2020 was an increased focus on physical health around the globe - and in turn, demand for athleisure apparel, activewear, and general sportswear spiked. The global fascination with this clothing continues, even after the fitness craze diminishes. So, what is the state of fabric as a result? And what is sportswear made of going into 2023?
Sportswear is commonly made from a variety of materials and blends, the most popular includes polyester, nylon, and spandex. These synthetic fibers are lightweight, durable, and moisture-wicking; ideal for activewear. A rising trend is replacing synthetic fibers with recycled and natural fibers.
Garments like bamboo, hemp, recycled polyester, and organic cotton are a few of the more sustainable fibers replacing synthetic fibers, but there's a long road ahead. For now, let's look at the 5 most popular fibers of fashion, then bring it back to sportswear.
What Material Is Sportswear Made From?
Sportswear is an incredibly broad term that can refer to anything from yoga pants to team jerseys and everything in between. The type of sportswear you're talking about will dictate the fabric it's made from.
For example, activewear like leggings, sports bras, and tank tops are often made from a polyester/spandex blend and are also increasingly using more sustainable fabrics. This blend is lightweight, stretchy, and moisture-wicking - perfect for a workout.
On the other hand, soccer jerseys are often made from 100% polyester - a durable fabric that can withstand the rigors of the game, but is also starting to see a surge in recycled polyester.
But even the best-intentioned changes still leave much more work to reach a majority of sustainable clothing.
5 Most Popular Fibers in Technical Sportswear
Sportswear is most commonly made from a variety of synthetic fabrics - the five most popular materials used in sportswear are:
Polyester
Spandex/Elastane
Nylon
Merino Wool
MMCFs (Bamboo, Eucalyptus, etc.)
Because sportswear is so broad, this list covers a few expanded areas beyond traditional sports - such as cycling, yoga, rowing, etc. This expansion brought more variety that reflected activewear consumption of the past two years more accurately.
1. Polyester - It's Everywhere
Polyester is the most popular fabric in sportswear and athleisure for several reasons - it's cheap, it's durable, and it has a variety of properties that make it ideal for activewear. Polyester is often blended with other fabrics to create a more versatile garment.
For example, polyester is often blended with spandex to create a fabric with good stretch and recovery. This blend is often used in leggings, sports bras, and other compression garments. Polyester is also blended with cotton to create a fabric that is lightweight and breathable - perfect for summer activewear.
Additionally, manufacturers like Repreve have formalized relationships with many global sportswear brands to start using recycled polyester in place of virgin polyester. This effort is a small step in the right direction to make polyester a more sustainable fabric.
2. Spandex/Elastane - The Stretchy Stuff
Spandex, also known as elastane, is a synthetic fiber that was first developed in the 1940s. Known for comfort and performance, this fabric has incredible stretch and recovery properties - it can be stretched up to five times its original length and will return to its original shape when released.
This makes spandex an ideal fabric for activewear, commonly blended with polyester or cotton, as it allows for a full range of motion without compromising the integrity of the garment. Spandex is often used in leggings, yoga pants, compression garments, and swimwear.
Manufacturing spandex does use toxic chemicals; however, some spandex can be Recycled Claim Standard (RCS) certified, meaning it was created using at least 5% recycled materials.
3. Nylon - Strong and Durable
Nylon is a synthetic polymer that was first developed in the 1930s as a replacement for silk. This fabric is strong and durable, making it ideal for activewear garments that will see a lot of wear and tear.
Nylon is often used in sports bras, cycling shorts, and other compression garments as it provides a great deal of support. Additionally, nylon is often used as a reinforcement in other fabrics - for example, many sports bras have a nylon outer layer with a cotton or polyester inner layer.
When used for knit fabrics, it's ideal for swimwear because of its high stretch and sleek fit. It has moderate moisture-wicking abilities and low breathability, which makes it perfect for outerwear applications.
When nylon is used for woven fabrics such as softshell and ripstop, it’s easy to apply a durable water-repellent (DWR) treatment to help moisture bead up and roll off the surface of the fabric.
Some nylon can be recycled, and there are several manufacturers converting nylon nets into recycled nylon, but it's not nearly as popular as recycled polyester.
4. Merino Wool - The Natural Fiber
Merino wool is a type of wool that comes from the merino sheep, a breed that was originally from Spain but now can be found all over the world. This wool is incredibly soft and has excellent moisture-wicking properties, making it ideal for activewear.
Merino wool is often used in base layers and other garments that will be worn next to the skin as it's very gentle. It's also a popular choice for socks as it helps to regulate temperature and prevent blisters.
While merino wool is a natural fiber, it does require a lot of resources to produce - sheep need to be shorn every year, and the wool needs to be processed before it can be used. Additionally, merino wool is not as durable as synthetic fabrics and is more susceptible to pilling.
There are some innovations taking place with wool though - Nuyarn for instance is a company that creates yarns from merino wool that is 50% stronger and amps up everything you love about merino wool.
5. MMCFs - The "New" Player
MMCFs (Man-Made Cellulosic Fibers) are a "new" type of fabric that is made from wood pulp, a renewable and sustainable resource - this could be a variety of raw sources like eucalyptus, beech, bamboo, etc.
New is certainly in quotations here because some of these methods date back well over a hundred years, but in terms of new natural fibers, they are quite recent.
These fibers are often used as a replacement for polyester, nylon, and other synthetic fabrics in activewear garments.
MMCFs have many of the same properties as synthetic fabrics - they are strong and durable, have excellent moisture-wicking properties, and are quick-drying.
They also have some distinct advantages over synthetic fabrics - they are biodegradable, recyclable, and produced with far less energy than synthetic fabrics.
One of the most popular MMCFs on the market is TENCEL, which is made by Lenzing. TENCEL is often used in athletic wear, underwear, and socks as it's soft, absorbent, and has excellent moisture-wicking properties.
While many different types of fabrics can be used for activewear, these five are some of the most popular as we head into 2023. Each has its advantages and disadvantages, so it's important to choose the right fabric for the job.
The State of Clothing Fibers Through 2025
Sportswear, inclusive of activewear and all its subcategories, is one of the sections of fashion leading the charge in sustainable apparel. But there will continue to be an overwhelming overreliance on synthetic fibers well into the future.
Since 1985, polyester has grown at an alarming rate - in that time, production has increased by nearly a 1000%. And it doesn't look like it's slowing down anytime soon. It's projected that by 2025, over half of all clothing will be made from polyester.
Nylon is another synthetic fiber in the top 5 most-produced fibers (polyamide) with a large carbon footprint and grew in production by 150% over the same timeframe as polyester.
While the natural fibers in the list, such as cotton, MMCFs, and other plants each grew, the MMCFs had the highest growth rate, just below 300% growth between 1985 and 2025.
What are MMCFs?
MMCF stands for man-made cellulosic fiber, which is derived from wood pulp. It's often used as a more sustainable alternative to viscose/rayon and has a lower carbon footprint. Lyocell and modal are two types of MMCFs that are made from wood pulp and are often found in sportswear.
Now, the Sport Casuals blog has covered MMCFs at length, so this won't go into every detail around MMCFs, but if you're curious to learn more, the below links will show you everything you could possibly want to know about man-made cellulosic fibers.
Synthetic fibers will continue to play an all too major part in the role of apparel unless a dramatic change occurs. Even though the top five most-produced fibers had significant growth, polyester is produced more than the other top 5 combined every year.
So if sportswear is marching to the beat of a different drummer, how does it play into this?
Does It Matter What Technical Sportswear Is Made Of?
Athletic apparel should be comfortable, and forgettable: in the sense that the wearer isn’t distracted by their apparel, how it fits, or whether it’s moving with their body, pinching uncomfortably, sliding, and more.
We work with clients to select the right fabrics for apparel designs to reduce and eliminate function and fit issues.
Thermal regulation is also very important, and a garment’s ability to offer temperature control on its own or when layered with other pieces is key when designing not only individual garments but also as part of a collection.
Considering how garments will feel when paired extends beyond temperature, even heading into the sensation of the fabrics sliding past each other or sticking together.
And at the end of the day, looks do matter.
Attractive apparel can inspire, motivate and generate a natural boost of energy, and any apparel that can transition from athletic pursuits to daily life is something customers will reach for more often.
Mesh panels, laser-cut detailing, sleek zippers, ergonomic seams, and attractive prints can take a simple style up a notch. Keeping fabric types and strengths in mind when applying these details makes a world of difference in the fit, function, and style of a garment.
Customers look to you for technical sportswear that will get the job done, but this type of apparel can go so much deeper than function. It’s up to you to guide your customers to the right pieces, and we’re here to help.
Know What Your Sportswear Is Made of
Many consumers are savvy and curious, they want to know more about the function, origin, and sustainability of items in their wardrobe.
Anyone who's headed out for a run and experienced chafe wearing a cotton t-shirt, or felt restricted in inflexible apparel while weightlifting knows the importance of selecting activewear that supports their activities.
However, newcomers to fitness may not know what to wear to prioritize comfort and performance. It’s up to brands to provide them with options and tell them how and why technical sportswear makes a difference.