he best tracksuit materials for activewear brands combine moisture-wicking, stretch, durability, and style. Blends like polyester-spandex, nylon, and cotton-poly offer the best performance across fitness, fashion, and function.
For activewear brands aiming to build loyalty and scale globally, material choice isn’t just a detail—it’s a strategy. The right fabric transforms movement, improves comfort, and boosts brand image. Let’s explore which tracksuit materials win in 2025’s performance-driven fashion landscape.
Why is polyester the most popular tracksuit fabric?
Cheap poly blends can feel plastic—but performance polyester is the workhorse of modern activewear.
Polyester tracksuit fabric is durable, lightweight, and moisture-wicking, making it the top choice for high-performance, all-weather activewear brands.
Polyester is widely used because it checks key boxes: fast drying, wrinkle-resistant, easy to sublimate, and durable under stress. For tracksuits, it holds shape even after repeated wear. It also performs well in humid or high-sweat environments. Adding spandex makes it stretch, while brushed finishes improve softness. Polyester is also relatively low-cost, which gives brands better margins. The downside? It’s petroleum-based and not biodegradable—but recycled polyester (rPET) solves part of that.
| Polyester Feature | Benefit | Best Use |
|---|---|---|
| Moisture-wicking | Keeps skin dry | Gym tracksuits, running sets |
| Shape retention | Doesn’t sag or stretch out | Slim-fit tracksuits |
| Printability | Sharp sublimation printing | Custom brand graphics |
Is nylon a better option than polyester?
Both nylon and polyester are synthetic—but nylon brings different strengths.
Nylon offers greater strength and abrasion resistance than polyester, making it ideal for outdoor tracksuits and rugged athletic use.
Nylon is smoother and stronger than polyester. It’s the go-to for tracksuit shells, windbreakers, and hybrid performance layers. It resists tearing and has a natural sheen that makes it look more premium. Nylon absorbs slightly more moisture but dries quickly. Combined with spandex, it forms a flexible and durable fabric ideal for tough workouts and outdoor use. For brands focused on elite training wear or tactical style, nylon blends are a smart pick.
| Nylon Strength | Ideal Application | Added Value |
|---|---|---|
| High abrasion resistance | Track jackets, tactical sets | Long product lifespan |
| Smooth texture | Premium training wear | Sleek, technical appearance |
| Stretch when blended | Full-range movement | Comfort under motion |
Why add spandex to tracksuit fabrics?
Without stretch, your tracksuits won’t move the way your customers do.
Spandex (also called elastane or Lycra) is essential in tracksuits for flexibility, comfort, and motion recovery. Even 5% spandex can transform the feel of the fabric.
Spandex is rarely used alone—it’s blended into polyester or nylon to add stretch. This is critical for slim-fit or performance tracksuits, where flexibility matters. It helps the fabric “snap back” after stretching, keeping the garment looking sharp. Brands that skip spandex often deal with saggy knees and loose cuffs. However, too much spandex can retain heat or feel tight, so blends must be optimized.
| Spandex % | Stretch Profile | Ideal Product |
|---|---|---|
| 3–5% | Light stretch for structure | Standard joggers, sweatpants |
| 6–10% | High mobility and recovery | Slim-fit training sets |
| 10%+ | Compression level stretch | Yoga or sculpting tracksuits |
Is cotton still relevant for tracksuits?
Cotton blends offer softness and breathability, ideal for athleisure tracksuits and cooler-weather wear, though they absorb more sweat than synthetics.
Cotton-polyester blends (like French terry) combine softness with moderate moisture control. They feel natural on skin and are great for warm-up or lounge tracksuits. Many lifestyle brands use brushed cotton for that cozy interior. Cotton is also biodegradable, making it more sustainable. For brands that want to straddle sport and style—or need a winter layering piece—cotton blends are hard to beat.
| Cotton Blend | Comfort Level | Best Use Case |
|---|---|---|
| 60/40 Cotton/Poly | Warm and breathable | Lounge or streetwear sets |
| French Terry Knit | Loop-back for softness | Warm-up tracksuits |
| Cotton-Spandex | Natural feel + stretch | Casual activewear sets |
What about fleece, loopback, and specialty knits?
Fleece, loopback jersey, and scuba knits offer warmth, structure, and softness, making them perfect for winter tracksuits or fashion-focused athleisure.
Fleece tracksuits are made from brushed polyester or cotton blends. They trap heat without adding weight. Loopback jersey (like French terry) is breathable with light insulation. Scuba knit, a thick double-knit polyester blend, creates sleek silhouettes and holds structure. These materials work for post-workout wear, travel tracksuits, or designer athleisure drops. Be mindful of pilling and shrinkage in lower-end fleece.
| Specialty Fabric | Key Feature | Seasonal Use |
|---|---|---|
| Fleece | Soft, brushed interior | Winter workout gear |
| Loopback (French Terry) | Breathable warmth | Mid-season tracksuits |
| Scuba Knit | Structured, stretchy surface | Fashion tracksuits, statement sets |
Can tracksuits be sustainable?
Sustainable tracksuits use recycled polyester, organic cotton, bamboo blends, and ethical production to appeal to eco-conscious consumers.
Consumers want comfort and conscience. Recycled polyester (rPET) saves waste and reduces carbon. Bamboo rayon offers breathability and softness. Hemp blends are durable and antimicrobial. These fabrics suit eco-friendly brands that prioritize values alongside performance. Also look for OEKO-TEX, GRS, or BSCI-certified suppliers to validate your green claims.
| Sustainable Fabric | Eco Benefit | Application |
|---|---|---|
| rPET (Recycled Poly) | Diverts waste, low impact | Everyday performance sets |
| Bamboo Viscose | Breathable, renewable | Lounge or hybrid tracksuits |
| Organic Cotton | Non-toxic, soil-safe farming | Mid-weight comfort sets |
Conclusion
The best tracksuit materials for activewear brands combine function, comfort, and brand identity. Polyester and nylon blends offer elite performance. Cotton blends and fleece serve lifestyle comfort. Spandex ensures stretch. Sustainable fabrics connect with conscious customers. Smart material choices not only improve product quality—they also shape your reputation and set your label apart in the global activewear market.
