Custom & Private Label Sports Bra Manufacturer | Sewn & Heat-Bonded
GYMHUR is a direct-to-brand custom sports bra manufacturer based in Sialkot, Pakistan. We produce private label high-impact sports bras, yoga bras, and seamless training bras for activewear brands, fitness studios, and online retailers worldwide. We offer two distinct construction methods: traditional 4-needle flatlock cut & sew for maximum structural durability, and advanced heat bonding using ultrasonic welding and structural adhesive films for a completely seamless, zero-chafe second-skin finish. Minimum order quantity starts at 50 pieces per design.
- Fabric: Nylon/Spandex or Polyester/Spandex (4-Way Stretch)
- GSM: 200–300 GSM (support level dependent)
- Stitching: 4-Needle Flatlock Cut & Sew OR Advanced Heat Bonding
- Styles: Racerback, Strappy, Longline, Zip-Front, Crop, Classic
- Support Levels: Low Impact (yoga) / Medium Impact (training) / High Impact (running, CrossFit)
- MOQ: 50 Pieces per Color
Custom & Private Label Sports Bra Manufacturing Services
At GYMHUR, we specialise in private label sports bra manufacturing for global activewear brands, yoga studios, gym wear labels, and fitness retailers. As a leading OEM factory based in Sialkot, Pakistan, we provide end-to-end production from sourcing butter-soft Nylon/Spandex and Polyester/Spandex blends to cup moulding, custom branding, and retail-ready packaging.
Every sports bra we produce is engineered to its specific support requirement: high-compression fabrics with reinforced underwire channels for high-impact running and CrossFit bras, lightweight 4-way stretch blends for low-impact yoga collections, and medium-support constructions for everyday training. Whether you are launching a performance activewear brand, building a luxury yoga line, or expanding into seamless construction, GYMHUR delivers the manufacturing precision your brand demands.
Manufacturing Versatility: Sewn or Bonded
We offer two distinct construction methods to match your brand’s specific market positioning:
- Traditional Cut & Sew (High Durability) Ideal for high-impact training, CrossFit, and running bras. We use 4-needle, 6-thread flatlock machines to create reinforced seams with maximum structural integrity. This method supports complex multi-strap designs, underwire channels, and heavy-compression panels. Fabric: 240–300 GSM Nylon/Spandex for maximum bounce control.
- Advanced Heat Bonding (Seamless Technology) Ideal for luxury yoga, pilates, and “second-skin” collections. We use structural adhesive films and ultrasonic welding to construct the entire garment without thread — creating raw-cut edges that lie perfectly flat against the skin for a zero-chafe finish. Fabric: 200–240 GSM soft-touch Nylon/Spandex.
Style Variants & Support Levels
We manufacture all major sports bra styles to OEM specification:
- Racerback: Classic high-support cut, ideal for running and high-impact training. Wide underband, narrow back straps that converge at the spine.
- Strappy / Multi-Strap: Fashion-forward cut popular for boutique fitness and yoga brands. Decorative back strap configurations with medium support.
- Longline: Extended cut that covers the midriff, popular for yoga and low-impact training. Available in crop or full-coverage lengths.
- Zip-Front: Front-closure zip design for easy on/off. High support, popular for post-surgery recovery wear and high-impact sport.
- Classic / Standard: Scoop or square neckline with medium support. The most versatile cut across price points and markets.
Why Choose GYMHUR?
We support activewear startups and established brands with flexible MOQs starting at 50 pieces per design — lower than most competing manufacturers who require 100 pieces minimum. By manufacturing directly with our Sialkot factory, you eliminate middleman costs, protect your designs under strict NDA, and gain full control over your supply chain. Contact us to start sampling your private label sports bra collection.
How to Manufacture Your Custom Sports Bra with GYMHUR
1. Submit Your Tech Pack
Send us your Tech Pack, reference samples, or design files. We will review your fabric requirements, support level, cup construction, sizing charts, and branding details and provide a precise manufacturing quote within 24 hours.
2. Prototyping & Sampling
Before bulk manufacturing, we source your specific Nylon or Polyester/Spandex blend, cut to your pattern, and create a pre-production sample. You test the fit, support level, cup setting, and construction method before any bulk commitment.
3. Bulk Production & QC
Once your sample is approved, we move to bulk production using 4-needle flatlock or heat bonding equipment and strict inline Quality Control at every stage — fabric inspection, mid-sew measurement checks, and final audit before packaging.
4. Global Delivery
We handle the logistics. Air freight via DHL or FedEx delivers your private label sports bras to the USA, UK, Europe, and Australia in 7–12 days. Sea freight for large bulk orders takes 25–40 days. Your order arrives fully packaged, labelled, and retail-ready.
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Frequently Asked Questions About Sports Bra Manufacturing
We select fabric based on the required support level. For high-impact bras (running, CrossFit, HIIT), we use a 240–300 GSM blend of 80% Nylon and 20% Spandex — high-compression, fully opaque, and engineered for maximum bounce control. For medium-impact training bras, we use a 220–240 GSM Polyester/Spandex blend. For low-impact yoga and pilates bras, we use a lighter 200–220 GSM soft-touch Nylon/Spandex for a second-skin feel and unrestricted movement. All fabrics are 4-way stretch.
Heat bonding (also called ultrasonic welding) is a seamless construction method where structural adhesive films are used to join fabric panels together without thread. Instead of stitching, panels are fused using heat and pressure, creating a completely smooth seam that lies flat against the skin with zero raised edges. This eliminates chafing entirely, making it ideal for luxury yoga and second-skin activewear collections. Traditional flatlock stitching, by contrast, creates a flat but visible seam and is better suited for high-impact bras that require maximum structural durability.
Yes, we offer full OEM cup customization. You can choose traditional slit pockets for removable pad inserts, or opt for our premium Bonded Pad Setting. Thermal fusing locks the cups perfectly in place so they never fold, shift, or bunch up during intense workouts or machine washing.
We manufacture all major sports bra styles to OEM specification: racerback (high support, ideal for running), strappy and multi-strap (medium support, popular for boutique fitness brands), longline (low to medium support, popular for yoga), zip-front (high support, easy on/off closure), and classic scoop or square neck (versatile, medium support). All styles are available in both cut & sew and heat-bonded construction depending on your brand’s requirements.
Yes. We offer full OEM pattern grading from XS through to 3XL as standard. Extended sizing beyond 3XL is available on request with a custom grading fee. Our pattern team has experience grading sports bras for plus size fits specifically — accounting for the additional support, wider underband construction, and adjusted strap width required for larger cup sizes. MOQ of 50 pieces per size run applies.
Pre-production sampling takes 10–21 days including pattern making and fabric sourcing. Heat-bonded styles may take 2–3 days longer than cut & sew due to the additional tooling setup. Once your sample is approved, bulk production averages 3–4 weeks depending on order volume. Air freight to the USA, UK, Europe, and Australia takes 7–12 days. Sea freight takes 25–40 days. Orders using in-stock fabric colours are processed faster than orders requiring custom dyeing.
Our MOQ for custom sports bras starts at 50 pieces per design or colourway — lower than most competing manufacturers who require 100 pieces minimum. This applies across all styles and construction methods, including heat-bonded and cut & sew. The 50-piece MOQ includes full private label finishing: silicone heat-transfer logos, custom woven tags, branded packaging, and retail-ready presentation.
Complete Your Activewear Collection
Custom Leggings
Custom Activewear
Ready to Start Production?
Bypass the middlemen and manufacture directly with GYMHUR. Upload your Tech Pack, design files, or simple sketches below. Our production team will review your specifications and send you a detailed pricing quote within 24 hours, or send us a message on WhatsApp below.