Custom Plus Size Yoga Wear Manufacturer
AIKA Sportswear is a vertically integrated manufacturer of custom plus size yoga wear, based in Dongguan, China. Since 2010, we have produced size-inclusive activewear for 320+ brands across the United States, United Kingdom, Germany, France, Netherlands, Ireland, and Australia.
We specialise in one thing that most factories overlook: making activewear that fits properly in extended sizes. We don’t simply grade up a standard pattern — we develop dedicated plus-size blocks using separate grading logic, so the fit stays true at 1X, 3X, and 5X. Our OEM/ODM service covers the full production chain: fabric sourcing, dedicated plus-size pattern development, sampling, bulk manufacturing, logo application, and private label packaging.
Bulk Custom Plus Size Yoga Types
As a plus size yoga activewear OEM factory with over 15 years of manufacturing experience, we offer full private label customisation for plus size yoga pants, leggings, tops, and sets. Send us your tech pack, reference designs, or purchase plan — our team will respond with a quotation and fabric recommendations within 24 hours.
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Common Sourcing Headaches When Buying Custom Plus Size Yoga
Patterns that are simply graded up from a standard block — resulting in armholes that open too wide, front bodies that feel short, and waistbands that roll during movement
Fabric that is squat-proof in size M but becomes sheer at 2X and 3X — because stretch percentage increases across the size range
Waistband construction that doesn’t account for body proportion changes — leading to constant readjustment during yoga practice
Inconsistent sizing across production runs — a 2X from one batch fits differently from the next
Only standard small sizing, no plus size & oversized tracksuit options
Uncertified factories with no BSCI or social compliance audit, creating compliance risk for EU and US buyers
How AIKA removes these risks:
- 1. Dedicated plus-size blocks developed from scratch using plus-size body measurement data — not simply scaled from a standard pattern
- 2.Every style is opacity-tested at the largest size in the range, not just the middle size
- 3.Anti-roll waistband construction with silicone grip and tested elastic recovery (minimum 95% recovery after 50 wash cycles)
- 4.Separate measurement tolerances defined per size grade to prevent batch-to-batch inconsistencies
- 5.BSCI-audited facility; SGS and OEKO-TEX certified materials
Our Key Benefits For Custom Tracksuit Buyers
Flexible MOQ for Brand Testing
Minimum order quantity from 100 pieces per style and colour. Mixed sizes (XS–5XL) and colourways accepted within one style to reduce inventory risk. Sample orders have no minimum quantity requirements for fabric and fit testing.
In-House ODM Design Team — From Concept to Bulk Delivery
Our in-house team handles fabric sourcing, pattern development, sampling, bulk manufacturing, and logistics coordination. You focus on brand building; we manage production execution. No complete tech pack ready? We develop silhouettes from reference images, sketches, or competitor samples.
Fabric Expertise Across Muslim Clothing Categories
Specialised development across Nida crepe, Japanese crepe, satin, georgette, jersey knit, French terry, and 4-way stretch nylon spandex. Fabric opacity, colour retention, and hand feel tailored to your brand’s positioning. OEKO-TEX Standard 100 certified fabrics.
Full OEM Design Support
If you need design support, our OEM service provides a one-stop solution from trend insights to finished products. Our in-house design and manufacturing team can help you develop a unique muslim clothing line — whether for daily modest wear, prayer collections, or muslim sportswear.
Smart, Scalable Production
Digitally managed production lines ensure flexibility for both small batch runs and large seasonal orders — suitable for growing modest fashion labels and established brands.
Build a Brand Identity That Fits Every Body
We translate your brand concept into production-ready details with durable logo and printing crafts compatible with all performance fabrics across the full size range.
Customization
Unbranded Yoga clothing can be customized to reflect individual ideas. We turn blanks into brands.
Fabric Innovation
Four-way stretch, squat-proof opacity Anti-pilling Cooling fibers for hot yoga Optional antibacterial & odor-control finishes
Versatility
Our gym clothing is available in a variety of styles, colors, and sizes to suit specific needs.
Sustainability & Personalization
Recycled nylon, eco yarns available Custom prints & color palettes Partial pattern or signature design options
Fit and construction details engineered for plus-size bodies:
- 1. Wider waistband proportions with anti-roll silicone grip (scaled for extended sizes)
- 2. Gusseted crotch construction to reduce chafe and front-seam visibility
- 3. Adjusted rise and torso length for proper coverage during yoga poses
- 4. Seam placement reviewed at the largest size to prevent pulling and distortion
Fabric features that support your product claims:
- 1. Four-way stretch with opacity tested at the largest size in the range
- 2. Anti-pilling and colour fastness tested
- 3. Cooling fibers for hot yoga and summer collections
- 4. Optional antibacterial and odour-control finishes
OEM Premium Supplier For Activewear
About AIKA Sportswear — A Factory Built for Size-Inclusive Brands
Founded in Dongguan, China in 2010, AIKA was established by a core team with over 15 years of sportswear R&D and manufacturing experience. We built our factory to address the most common pain points reported by global clothing buyers: rigid high MOQ requirements, inconsistent fabric quality, slow sampling cycles, and non-standard customisation service.
As a vertically integrated manufacturer, we handle independent R&D, fabric sourcing, bulk production, and full OEM/ODM customisation. Our main products include plus size yoga pants, leggings, tops, sets, running sportswear, and blank workout apparel. We serve importers, boutique clothing brands, and Amazon & independent store sellers across the USA, EU, Australia, and Southeast Asia.
All fabrics pass SGS and OEKO-TEX international certification.
Our Complete 6-Step Development Process
We follow a strict and efficient workflow to bring your sportswear concepts from initial ideas to final bulk delivery smoothly.
Dedicated account manager assigned within 24 hours
After reviewing your customisation requirements, order quantity, and timeline, a dedicated consultant is assigned to your account.
Pattern development based on your design files
Our CAD designers create production patterns from your tech pack, design drawings, or reference samples. We accept AI, PDF, and tech pack files. For muslim clothing, pattern development includes modesty-compliant fit verification and coverage adjustment.
Fabric and colour confirmation with opacity and compliance verification
You receive fabric swatches with verified opacity data, colour cards, and compliance test reports (OEKO-TEX) for approval. We offer 12,000+ fabric and colour options, plus custom fabric development for specific opacity and drape requirements.
Cutting and pre-production sample
Fabric is pre-shrunk, tested for opacity, and cut according to approved patterns. A pre-production sample is produced for your approval before bulk cutting begins. Hijab edge construction and prayer dress length verified at this stage.
Bulk production with in-line QC
Flatlock, overlock, and coverstitch construction performed in-house. In-line quality checks at each production stage, including measurement verification, colour consistency spot-checks, and opacity verification.
Final inspection and shipment
100% full inspection with before packing. Compliance documentation provided for customs clearance. Photos and videos shared for your confirmation before dispatch.
Frequently Asked Questions
Served over 130 global fitness, yoga and activewear brands, repeat customer repurchase rate hits 98%. Free factory on-site inspection arrangement for clients with order quantity over 300 pcs, virtual video factory tour support for overseas buyers.
We produce from XS to 5XL (US 0–28 / UK 4–32). Plus-size sizes (1X–5XL) are developed using dedicated pattern blocks with separate grading logic — not simply scaled up from a standard pattern. For buyers testing the market, we offer size-inclusive sampling across XS–3XL at no minimum quantity requirement.
Standard MOQ is 100 pieces per colour and style. Mixed sizes (XS–5XL) are accepted within the same style to reduce inventory costs. Sample orders have no minimum quantity requirement.
es. We develop high-waist leggings, cross-back tops, seamless sets, flare pants, and pocket leggings in extended sizes. You provide a tech pack or reference images; our team offers free ODM pattern development. Customisable details include waistband height, inseam, gusset construction, labels, hangtags, and brand packaging.
We develop dedicated plus-size blocks using separate grading logic based on plus-size body measurement data. Fit models at sizes 1X and 3X are used during sampling. Separate measurement tolerances are defined per size grade, and every production batch undergoes measurement verification across the full size range — not just the middle size.
4-way stretch butter nylon spandex, ribbed knit, seamless compression fabric, quick-dry blends, GRS recycled fabric, and UPF 50+ matte material. Every fabric batch undergoes opacity testing at the largest size in the range, plus anti-pilling, colour fastness, and stretch recovery tests.
Pre-production samples take 5–15 working days after confirmation. Bulk orders require 25–35 working days. 15-day rush production is available for seasonal launches.
3D silicone print, water-based screen print, heat transfer, jacquard labels, embroidery, and all-over sublimation. All decorations resist cracking, peeling, and fading after repeated washing.
Yes. We are an integrated sportswear manufacturer with complete cutting, sewing, printing, and washing workshops — no middlemen. Buyers can book free online video tours at any time. On-site factory visits are available by prior appointment. Monthly capacity reaches 500,000 units.
No. We sign NDAs with all private label clients. Your exclusive silhouettes, patterns, and tech packs will never be shared with other brands. Pattern files are stored securely for future reorders with no additional pattern fees.
