The Complete Glossary of Activewear Manufacturing Terms Every Brand Should Know

AQL - Acceptable Quality Limit

AQL is a statistical sampling method used to determine whether a production batch passes quality inspection. For activewear, AQL 2.5 is the industry standard for major defects under ISO 2859-1. This means up to 2.5% of inspected units may have major defects and still pass. Critical defects (safety issues, opacity failure) have a zero tolerance AQL.

BOM - Bill of Materials

The BOM lists every component that goes into a garment: fabric (with yardage per unit), thread, zippers, elastic, labels, hang tags, polybags, and cartons. A complete BOM ensures the factory orders everything needed before production starts and prevents last-minute shortages that delay shipments.

BSCI - Business Social Compliance Initiative

BSCI is a social compliance framework that audits factories on fair wages, working hours, health and safety, and prohibition of child labor. Required by most European retailers. Ratings range from A (best) to E. A rating of C or better is typically needed to supply EU markets.

CAD - Computer-Aided Design

CAD software (such as Adobe Illustrator, CLO 3D, or Optitex) is used to create technical flat sketches, develop patterns, grade sizes, and optimize marker layouts. Modern CAD allows virtual garment simulation, reducing the number of physical samples needed.

Cut and Sew

A manufacturing method where fabric is cut into pattern pieces and then sewn together. This is the traditional approach used for most activewear including leggings, sports bras, and jackets. Contrasts with seamless knitting, where garments are produced directly on circular knitting machines with minimal cutting.

DUPRO - During Production Inspection

In-line quality control conducted when 20-30% of production is complete. DUPRO catches systemic issues early enough to correct them before the entire batch is finished. Particularly important for activewear where fit and construction issues compound rapidly.

ECONYL - Regenerated Nylon

ECONYL is a branded recycled nylon made from recovered fishing nets, fabric scraps, and industrial plastic waste through a regeneration process. It offers identical performance to virgin nylon with 80% lower global warming impact. Used in premium sustainable yoga leggings and swimwear.

FOB / CIF / DDP - Shipping Terms (Incoterms)

FOB (Free on Board): seller delivers goods to the port, buyer handles shipping from there. CIF (Cost, Insurance, Freight): seller covers shipping and insurance to the destination port. DDP (Delivered Duty Paid): seller handles everything including customs clearance and delivery to the buyer's door. Most first-time buyers prefer DDP for simplicity.

GSM - Grams per Square Meter

GSM measures fabric weight. For yoga leggings, 220-280 GSM is the standard range. Lower GSM (under 180) is sheer and suitable for layering; higher GSM (over 280) offers compression but may restrict movement. GSM alone doesn't determine quality — fiber composition, knit structure, and finishing also matter.

Incoterms

International Commercial Terms that define buyer and seller responsibilities in shipping contracts. The most common in activewear sourcing are FOB, CIF, and DDP. Your choice of Incoterm significantly affects total landed cost and should be discussed with your manufacturer before placing an order.

Lab Dip

A small fabric swatch dyed to match a specific Pantone or brand color reference. Lab dips are created before bulk dyeing and must be approved by the buyer. Each lab dip round takes 3-5 days. Budget for 2-3 rounds to get color exactly right, especially for brand-specific colors.

MOQ - Minimum Order Quantity

The smallest number of units a factory will produce in a single production run. For activewear, MOQs range from 50-100 pieces per style for private label, 100-300 for ODM modifications, and 300-500+ for full custom OEM. Always clarify whether MOQ is per style, per color, or total across all variants.

OEKO-TEX Standard 100

An independent certification system that tests textile products for harmful substances. For activewear, Class II certification covers skin-contact garments. The standard tests for over 1,000 substances including formaldehyde, heavy metals, PFAS, and pesticides.

PP Sample - Pre-Production Sample

The final sample made before bulk production, using the same fabric, trims, and construction methods as the bulk order. PP sample approval is the gate that opens bulk production. Never approve a PP sample without testing fit, fabric feel, and construction quality first.

Tech Pack

The complete technical document that tells a factory exactly how to manufacture a garment. Includes: flat sketches with front and back views, graded spec sheet with measurements for all sizes, bill of materials, construction details, color specifications (Pantone codes), artwork placement diagrams, and packaging instructions. A thorough tech pack is the single most important tool for getting accurate samples and consistent bulk production.

rPET - Recycled Polyester

Polyester fiber made from recycled PET plastic bottles. rPET performs nearly identically to virgin polyester but uses 59% less energy and produces 32% fewer CO2 emissions. GRS (Global Recycled Standard) certification verifies recycled content claims. Increasingly expected by eco-conscious brands and retailers.

Understanding these terms will dramatically improve your communication with manufacturing partners. Bloomto's team is always available to explain any term or process in detail. Contact us with questions about your activewear project.