How We Cut Fit-Related Returns by 10% | Custom Women's Yoga Set for Australian Sustainable DTC Brand

Client Overview

Our client is an Australian premium DTC sustainable activewear brand, selling yoga & pilates apparel direct to female consumers. Their core audience prioritizes eco-friendly fabric, comfortable fit and squat-proof performance. They partnered with Bloomto to develop a women's 2-piece yoga set (sports bra + high-waisted leggings) for their new seasonal collection.

The Challenge

Before working with Bloomto, the brand faced three critical pain points hurting their business:

• Fit issues drove high return rates: Previous manufacturer's pattern was not optimized for Western body shapes. Waist roll-down, crotch slipping and inconsistent sizing created frequent customer complaints, and fit-related returns were eating into their profit margin.
• Difficulty sourcing compliant sustainable fabric: They needed GRS-certified recycled fabric that was PFAS-free, with soft handfeel, stable compression and squat-proof performance. Many suppliers could not deliver complete test reports to meet AU & EU textile regulations.
• High minimum order quantities blocked market testing: Most factories required large batch orders, making it financially risky for the brand to test new styles before scaling up.

Our Solution

Bloomto delivered end-to-end ODM customization tailored to the brand's sustainable yoga set requirements:

• Fit engineering & pattern revision: We reworked the high-rise waistband and leggings pattern for Australian female body proportions. Multiple fit samples were iterated to eliminate waist slipping, improve butt-lifting shaping and standardize sizing across all sizes.
• Sustainable fabric solution: We selected GRS recycled polyester-spandex blend fabric, fully PFAS-free, and supplied complete test certificates to satisfy Australian and EU market compliance requirements.
• Controlled sampling, QC & flexible low MOQ: We shortened sampling turnaround, with a clear MOQ of 100 units per style per color, ideal for brand market testing. Full in-house quality checks were implemented at cutting, sewing and packing stages. BSCI audit documentation is available for brand review.
• Custom branding elements including woven labels, care tags and logo placement were implemented following the brand's tech pack.

Results

• Fit-related return rate reduced by 10% after switching to Bloomto's optimized pattern; fewer customer complaints about waist roll-down and sizing inconsistency.
• Sampling finalized within 8 days after tech pack confirmation, allowing the brand to launch the collection on schedule.
• The yoga set is fully GRS verified and PFAS-free, meeting all textile compliance requirements for Australia and EU sales.
• This yoga 2-piece set became one of their top-selling hero SKUs. Positive customer feedback drove repeat orders and expanded their seasonal product lineup.
• Lower return volumes cut the brand's logistics, restocking and customer service costs, improving overall product profit margin.
• Long-term stable partnership established; the brand continues to develop new activewear styles with Bloomto.

Client Testimonial

Summary

Bloomto specializes in OEM & ODM custom women's yoga sets for global sustainable activewear brands. We help DTC brands resolve costly fit problems, source PFAS-free / GRS certified fabrics, and run low-risk test orders with our MOQ of 100 units per style per color. Whether you need ODM ready styles or fully custom development from your tech pack, Bloomto supports your project from sampling to mass shipment.