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Choosing the right fabric is critical for custom activewear. From Brisbane humidity to Melbourne cool, we guide Australian brands, clubs, and gyms through the ideal composition, GSM, and performance specs for every garment.
Bulk Manufacturing for Clubs & Schools
GSM means Grams per Square Metre.
It indicates the approximate weight and density of a fabric.
Generally:
However, GSM alone does not determine fabric quality.
A 180 GSM polyester fabric and a 180 GSM nylon-spandex fabric can feel and perform completely differently because fibre composition, knitting structure, finishing and stretch characteristics also matter.
Typical composition: 100% Polyester
Typical GSM: 120–180 GSM
Polyester is one of the most widely used fibres for sportswear because it is lightweight, durable and suitable for moisture-management finishes.
For Australian teamwear, polyester is particularly popular for sublimated jerseys and performance shirts.
Typical composition: 90–95% Polyester + 5–10% Spandex
Typical GSM: 140–220 GSM
Adding spandex provides stretch and improves freedom of movement.
This is a versatile choice for modern activewear.
For general-purpose performance activewear, 92–95% polyester + 5–8% spandex is a practical starting point.
Typical composition: 70–80% Nylon + 20–30% Spandex
Typical GSM: 180–250 GSM
Nylon-spandex is one of the premium choices for fitted activewear.
It offers a smooth hand feel, excellent stretch and good recovery.
A common premium specification is approximately 80% Nylon + 20% Spandex at 220–240 GSM for leggings and fitted performance garments.
Typical composition: 75–85% Nylon + 15–25% Spandex
Typical GSM: 150–190 GSM
This version is better when the brand wants a lighter and more breathable garment.
It can be particularly suitable for warmer Australian conditions.
Typical composition: 65–75% Nylon + 25–35% Spandex
Typical GSM: 220–300 GSM
Higher spandex content and heavier construction can provide a stronger compressive feel.
This fabric should be selected carefully because excessive compression is not appropriate for every activity or customer.
Typical composition: 65–75% Polyester + 20–30% Rayon + 5–10% Spandex
Typical GSM: 160–220 GSM
This blend provides a softer, more lifestyle-oriented feel compared with traditional performance polyester.
Rayon can provide a soft and comfortable hand feel, while polyester contributes durability and spandex provides stretch.
Typical composition: 60–70% Cotton + 30–40% Polyester
Typical GSM: 160–220 GSM
Cotton-polyester blends are popular for casual sportswear and gym lifestyle clothing.
However, cotton is generally less suitable than technical synthetic fabrics for extremely high-sweat performance applications.
Typical composition: 60–70% Cotton + 25–35% Polyester + 3–7% Spandex
Typical GSM: 180–240 GSM
This combination adds stretch to a comfortable cotton-polyester base.
It is particularly suitable when comfort and casual appearance are more important than maximum technical performance.
Typical composition: 70–80% Polyamide + 20–30% Spandex
Typical GSM: 180–250 GSM
Polyamide is another name commonly used for certain nylon fibres.
Polyamide-spandex fabrics are popular for premium fitted activewear because they can provide excellent stretch, softness and recovery.
Typical composition: 100% Polyester
Typical GSM: 100–160 GSM
Microfiber polyester can provide a lightweight and smooth fabric suitable for performance garments.
This is a useful option when low garment weight and quick drying are priorities.
Typical composition: 100% Polyester
Typical GSM: 140–220 GSM
Interlock is a knitted fabric construction rather than a fibre itself.
It generally provides a smoother and more substantial feel than very lightweight jersey constructions.
Typical composition: 100% Polyester or Polyester blend
Typical GSM: 150–220 GSM
Pique fabrics have a textured surface and are particularly common in performance polo shirts.
Typical composition: 100% Polyester
Typical GSM: 80–150 GSM
Mesh is designed to increase ventilation and airflow.
Mesh can also be strategically combined with other fabrics to create ventilation zones.
Typical composition: 90–95% Polyester + 5–10% Spandex
Typical GSM: 100–160 GSM
Adding spandex provides additional stretch while maintaining breathability.
Typical composition: Polyester + Spandex or Nylon + Spandex
Typical GSM: 200–300 GSM
Scuba-style fabrics are thicker and structured compared with lightweight performance fabrics.
It is generally more suitable for fashion-focused activewear than extremely lightweight running apparel.
Typical composition: Usually Polyester or Polyester + Spandex
Typical GSM: 130–180 GSM
Performance jersey is a broad category used for lightweight sports tops.
It provides a good balance between weight, comfort and performance.
Typical composition: Nylon/Polyamide + Spandex or Polyester + Spandex
Typical GSM: 200–300 GSM
Compression fabrics are engineered to provide a close-fitting, supportive feel.
The correct composition depends on the desired compression level and garment construction.
Typical composition: Polyester + Spandex or Nylon + Spandex
Typical GSM: 180–260 GSM
The inside of brushed fabric is mechanically treated to create a softer surface.
This can be useful for cooler Australian regions and winter collections.
Typical composition: Polyester or Cotton/Polyester
Typical GSM: 240–400 GSM
Fleece is primarily used for warmer garments rather than high-intensity summer sportswear.
Typical composition: Cotton + Polyester
Typical GSM: 280–400 GSM
Cotton fleece provides a comfortable and heavier premium feel.
Typical composition: Cotton, Cotton/Polyester or Cotton/Polyester/Spandex
Typical GSM: 220–350 GSM
French Terry is lighter than many fleece constructions and works well for transitional-season garments.
Typical composition: Nylon/Polyamide + Polyester + Spandex
Typical GSM: 180–280 GSM
Seamless activewear is generally manufactured using specialised knitting processes rather than conventional cut-and-sew construction.
It can provide a clean appearance and reduce the number of traditional garment seams.
Typical composition: Recycled Polyester (rPET)
Typical GSM: 120–220 GSM
Recycled polyester is manufactured from recycled polyester sources and can be used in various performance fabrics.
Brands targeting sustainability-conscious Australian consumers may consider recycled polyester where appropriate.
Typical composition: Recycled Nylon + Spandex
Typical GSM: 180–250 GSM
This provides an alternative for premium activewear brands wanting a recycled fibre option.
The exact recycled content and certification should always be confirmed with the fabric supplier.
Typical composition: Polyester, Nylon or blended technical fibres
Typical GSM: 120–220 GSM
Some fabrics and garment constructions can provide enhanced UV protection. However, UPF should not be claimed simply because a fabric is polyester or has a particular GSM.
If your product is marketed as UPF 50+, the finished garment should be appropriately tested and certified against the applicable Australian requirements.
| Fabric | Typical Composition | Typical GSM | Best Applications |
|---|---|---|---|
| Polyester | 100% Polyester | 120–180 | Jerseys, running, teamwear |
| Polyester Spandex | 90–95% Polyester / 5–10% Spandex | 140–220 | Training & activewear |
| Nylon Spandex | 70–80% Nylon / 20–30% Spandex | 180–250 | Leggings & premium activewear |
| High Compression | 65–75% Nylon / 25–35% Spandex | 220–300 | Compression wear |
| Polyamide Spandex | 70–80% Polyamide / 20–30% Spandex | 180–250 | Yoga & premium activewear |
| Polyester Rayon Spandex | 65–75% Polyester / 20–30% Rayon / 5–10% Spandex | 160–220 | Premium gym tops |
| Cotton Polyester | 60–70% Cotton / 30–40% Polyester | 160–220 | Casual sportswear |
| Cotton Polyester Spandex | 60–70% Cotton / 25–35% Polyester / 3–7% Spandex | 180–240 | Gym & lifestyle wear |
| Microfiber Polyester | 100% Polyester | 100–160 | Running & lightweight tops |
| Polyester Mesh | 100% Polyester | 80–150 | Ventilation & jerseys |
| Polyester Mesh Spandex | 90–95% Polyester / 5–10% Spandex | 100–160 | Performance tops |
| Scuba | Polyester/Nylon + Spandex | 200–300 | Premium activewear |
| Fleece | Polyester / Cotton Polyester | 240–400 | Hoodies & winter wear |
| French Terry | Cotton/blends | 220–350 | Joggers & sweatshirts |
| Seamless | Nylon/Polyester + Spandex | 180–280 | Seamless activewear |
| Recycled Polyester | Recycled Polyester | 120–220 | Sustainable sportswear |
| Recycled Nylon Spandex | Recycled Nylon + Spandex | 180–250 | Sustainable leggings |
| UV Performance | Polyester/Nylon technical blends | 120–220 | Outdoor sportswear |
Xwears is Australia's leading specialized manufacturer for custom activewear, gym clothing, and professional sports uniforms. Our expertise in sublimation, embroidery, and screen printing allows us to provide high-performance solutions for brands and teams globally.