10 Best Plus Size Activewear Manufacturers Trusted by Brands in 2025

The average American woman wears a size 16, yet plus size activewear manufacturers remained overlooked in the fitness apparel industry for years.

As a professional custom sportswear manufacturer, we know more people now just need inclusive sportswear as they adopt fitness and healthy lifestyles. The market has responded with quality-focused manufacturers producing sizes up to 7XL.

This piece highlights the 10 most trusted plus size activewear manufacturers as we approach 2025. These companies help your brands grow their size range. They also cater to anyone looking for plus-size activewear. They go beyond meeting market needs – they champion body positivity and redefine performance wear for every body type.

List Of 10 Best Plus Size Activewear Manufacturers

Quick Preview:

Manufacturer	Size Range	Key Features/Technologies	Manufacturing Location/Practices	Sustainability Initiatives
Girlfriend Collective	Up to 6XL	“For Everyone Size” numbered system (1-12), Compression leggings and bras	SA8000 certified facility in Hanoi, Vietnam	Recycled materials (RPET), OEKO-TEX® certified, ReGirlfriend recycling program
Universal Standard	00-40 (4XS-4XL)	Universal Fit Liberty program, Premium breathable fabrics, Clean design	Multiple locations (China, Peru, France, USA)	Plastic-free packaging, Durable garments
Yitty by Fabletics	XS-6X	Three collections (Nearly Naked, Mesh Me, Major Label), Compression wear	Carbon-neutral certified facilities	60% recycled materials, Recycled packaging materials
Day Won	0-32	Antimicrobial fabrics, Sweat-wicking technology, Tested compression gear	U.S.-based (partnered with Ziel in NY)	Made-to-order production, Digital printing technology
Lola Getts	XS-4X	Three compression levels, Different patterns for plus/straight sizes	U.S.-based manufacturing	Not mentioned
Alala	1X-3X	Breathable mesh tops, Seamless sports bras, Smart seam placement	Not mentioned	Recycled fabrics, Plant-based fibers, Local materials
Halara	Not specified	Patitoff 2.0, Softlyzero, Breezeful, Cloudful fabric technologies	Not mentioned	Not mentioned
PopFlex Active	XXS-3XL	Anti-cameltoe technology, Non-see-through fabric, Multiple waistband styles	Not mentioned	Antimicrobial fabrics
Juno Active	XL-6X	SoftWik®, QuikEnergy, AquaSport technologies, UPF 50 protection	Minnesota-based	Durable materials
Athleta	XXS-3X	Sweat-wicking technology, Hidden pockets, D-DD+ sports bras	Not mentioned	Certified B Corp, Recycled materials, Plans to cut GHG emissions by 90%

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1. Girlfriend Collective

Ellie and Quang Dinh, a couple from Seattle, started Girlfriend Collective. Their brand is unique among best plus size activewear manufacturers. They focus on sustainability, ethical practices, and size inclusivity. The brand has quickly become a favorite among consumers and retailers. They seek partners who practice responsible manufacturing.

Girlfriend Collective’s inclusive sizing up to 6XL

The brand started with sizes up to 3XL and made waves by expanding to 6XL. This makes them one of the most size-inclusive activewear manufacturers today.

The brand created their “For Everyone Size” approach—a numbered 1-12 system that matches standard men’s and women’s sizing. Their clothing becomes available whatever the customer’s gender.

Their inclusive approach goes beyond larger sizes. They feature diverse models with different body types, sizes, and skin tones in their marketing. This helps customers see how products will fit their body shapes.

Girlfriend Collective’s recycled materials and certifications

The brand shows their dedication to sustainability through recycled materials:

• Compressive leggings and bras: Made from 79% recycled polyester (RPET) and 21% spandex
• Each pair of leggings contains approximately 25 recycled post-consumer water bottles
• Each bra uses approximately 11 recycled water bottles
• LITE leggings: Crafted from recycled fishing nets using ECONYL® yarn (83% recycled nylon, 17% spandex)
• T-shirts and tanks: 100% cupro, made from cotton industry’s waste

The brand’s eco-credentials come with respected certifications. The Global Recycled Standard checks their recycled polyester. This ensures it uses real recycled materials and is processed without harmful chemicals. Their OEKO-TEX® certified fabrics guarantee freedom from harmful substances.

2. Universal Standard

Universal Standard is one of the best plus size activewear manufacturers. They have changed the game by focusing on size inclusivity. The brand has given new meaning to inclusive fashion since 2015 by creating quality, minimalist pieces that work for every body type.

Universal Standard’s size range and fit breakthroughs

The brand offers the widest size range you’ll find anywhere – from 00 to 40 (4XS to 4XL). This comes from their belief that “a size 6 should have the same shopping experience as a size 36”. They take a fresh look at sizing by using the real average American size (18) as their starting point, instead of the typical industry sample sizes 6 or 8.

Universal Standard’s minimalist design and quality

Quality materials and clean design set Universal Standard apart. Their athleisure line combines “performance-ready functionality with effortless, everyday style” using premium, breathable fabrics.

Their activewear focuses on comfort over intense performance gear. You’ll find:

• Relaxed fits that work well if you don’t like compression
• Straps you can adjust to fit different heights
• Silky-feeling cupro blends that let your skin breathe
• Fabrics that resist wrinkles and stay fresh all day

The clothes last for years. One customer still loves her leggings after almost ten years. Another customer wears the original leggings from when the brand first launched activewear in 2018.

Universal Standard’s manufacturing transparency

While Universal Standard shares less sustainability info than others, they stick to strong ethical standards. The founders check every factory themselves across China, Peru, France, and the USA.

This ethical mindset shows up everywhere in their business. They give Fit Liberty returns to groups like Dress for Success and use no plastic in their packaging. By focusing on quality fabrics and timeless styles, their clothes survive countless washes and stay wearable season after season – a key part of eco-friendly fashion.

Universal Standard helps brands find manufacturers who value size inclusivity, quality, and ethical practices in plus-size activewear.

3. Yitty by Fabletics

Grammy-award winning artist Lizzo teamed up with sportswear giant Fabletics to create Yitty in 2022. The brand has carved a special place among plus size activewear manufacturers. Yitty, named after Lizzo’s childhood nickname, started with shapewear and now includes lifestyle apparel, lingerie, and swimwear.

Yitty’s bold plus size activewear designs

Yitty stands out from regular shapewear brands. It offers a vibrant look and versatile collections. Yitty stands out with bold colors, striking prints, and modern shapes.

The brand’s product lineup has three signature collections:

• Nearly Naked: Traditional, seamless undergarments designed to smooth and lift
• Mesh Me: Fashionable mesh styles with varying levels of compression
• Major Label: Everyday loungewear pieces that double as streetwear

Yitty expanded into new categories like Smoothed Reality (intimates) and Headliner (shapewear meets partywear). These additions blur the line between inner and outerwear. This crossover strategy has shaped their design philosophy from the start.

Yitty’s manufacturing and design innovation

Yitty’s fashion-forward appearance comes from state-of-the-art manufacturing. They crafted over 60% of our fabrics from sustainable and recycled materials. This shows their steadfast dedication to environmentally responsible practices.

The brand has managed to keep its carbon-neutral certification since 2021 and operates under the CarbonNeutral Protocol. This certification includes their packaging. All polybags, mailers, cartons, and tissue materials are made from recycled materials.

Yitty uses innovative sizing techniques instead of just scaling patterns up or down. Their Vice President of Design explains, “We don’t simply grade patterns up or down—we ensure each size provides the same fit, support, and esthetic”. The team rethinks construction elements, adds specific design features for larger sizes, and tests extensively with real people.

Yitty’s inclusive sizing and body positivity mission

Yitty launched with sizes from XS to 6X. We want to redefine what inclusive fashion means. The brand exists to champion body diversity and self-confidence.

Lizzo played a hands-on role in the design process: “I have been very involved in the design of every style. I see every fabric, I pick every color, I’ve tried on every piece a ton of times throughout the design and fitting process”.

Pro Tip: Are you still worried about finding high-quality custom t-shirts manufacturers or custom jacket manufacturers? Tell our professionals about your custom clothing ideas now, and you will have unexpected surprises.

4. Day Won

Day Won stands out among top plus size activewear manufacturers with its innovative on-demand production model. Their approach eliminates waste and delivers high-performance activewear in an impressive size range.

Day Won’s U.S.-based eco-friendly production

Their production method brings major environmental benefits. Day Won stops unwanted clothes and scraps from going to waste. They do this with on-demand manufacturing. This model helps reduce the fashion industry’s contribution to the 10.5 million pounds of excess clothing burned or sent to landfills each year.

Day Won reduces their environmental impact through:

• Digital printing technology that eliminates traditional dyeing processes
• Recycled materials in their signature styles
• Local manufacturing that reduces carbon emissions
• Water conservation through digital construction of prints

Day Won’s antimicrobial and sweat-wicking fabrics

Day Won’s fabrics address common activewear problems with their technical features. Their antimicrobial fabrics prevent bacteria, fungi, and odor-causing microbes from growing. This helps keep clothes fresh for a longer time. This technology prevents bacterial growth that often leads to skin irritation, rashes, and unpleasant odors.

The fabric’s moisture-wicking technology works with capillary action to pull sweat away from the skin. The fabric surface stays dry to touch, which prevents the clammy feeling you get with cotton and other non-performance fabrics. This technology helps regulate temperature, prevents chafing, and conceals excessive sweating.

Day Won’s size range and performance features

Day Won shows their dedication to size inclusivity with their complete size range from 0 to 32. All but one of these styles are available in every size, unlike brands that limit their plus-size options.

Performance stays a top priority alongside inclusivity. The styles employ compression fabrics tested in marathons, which ensures they work well during intense workouts. Leggings and other pieces cost between $19 and $89, making them more affordable than other premium activewear brands.

Day Won leads the plus-size activewear market. They blend eco-friendly practices with great performance and true size inclusivity.

5. Lola Getts

Lola Getts started as a plus-size exclusive brand and grew into one of America’s most detail-oriented plus size activewear manufacturers. The brand creates premium sportswear with a steadfast dedication to perfect fit.

Lola Getts’ U.S. manufacturing and quality control

Lola Getts stands out by manufacturing all products in the United States, unlike competitors who choose overseas production. Founder Stacey Goldstein believes that “quality control meant being able to go to a factory” to meet strict standards. The brand only partners with factories they have checked themselves. They say, “We would never sew in a factory without seeing their sample production.””

Lola Getts’ plus size fit and comfort

The brand’s unique fit approach sets them apart from other plus size activewear makers. They create separate patterns for plus and straight sizes. A size 16 fit model helps design plus sizes while a size 6 model works for size 12 and under. This method ensures that “whether straight or curvy, each category has its own sets of patterns, its own fit models, and its own production runs.”

Their fabric technology offers three compression levels suited for different activities:

• High compression: Maximum support during intense workouts
• Medium compression: Secure support for moderate activities
• Low compression: Comfort for low-impact workouts and lounging

The brand’s unique textured fabrics, tested on women of various shapes, create activewear that customers adore. Many say it helps them “feel strong and confident” with “workmanship [that] is stellar.”

Lola Getts’ best-selling activewear pieces

Leggings lead the brand’s product line. Customers praise how they “actually suck you in and stay up” and “do not ride down when you are working out.” Athletic tanks and capri leggings offer lightweight comfort through moisture-wicking, breathable fabric.

The brand offers sizes XS to 4X with consistent quality across the range. One satisfied customer shares, “they make me feel strong and confident and it’s obvious that the workmanship is stellar.”

6. Alala

Alala stands out among plus size activewear manufacturers. This minority female-founded company has a 100% women team. They create stylish, inclusive athletic wear.

Alala’s luxury activewear and size inclusivity

Alala breaks barriers in luxury activewear by offering sizes from 1X to 3X throughout their collection. Their leadership saw a real need here, since “two-thirds of women in America are a size 14 and above”. The brand launched the Superbodies collection. It features 11 styles in extended sizes. This shows their commitment to size inclusivity.

The brand creates versatile performance wear that works for morning workouts and everyday activities. Their collection includes:

• Breathable mesh tops with refined details
• Well-crafted seamless sports bras
• Performance leggings with elastic waistbands

Alala’s feedback-driven design process

Alala sets itself apart from other plus size activewear brands through its extensive customer feedback approach. The company spent over 16 months developing their inclusive line. They held “dozens of fitting sessions and made hundreds of adjustments” based on direct input from women who wear sizes 1X-3X.

This detailed process led to key improvements. The team made the straps more supportive. They also kept stylish details. They adjusted waistband heights for better comfort and fit.

Alala’s premium materials and durability

Alala shows its commitment to green practices through material choices. The brand features sustainable styles with “recycled fabric, plant based fibers, locally sourced materials, and biodegradation”.

The brand’s blend of premium quality with size inclusivity makes it a standout plus size activewear manufacturer. Each piece has smart details, like strategic seam placement and support designed for plus size bodies.

7. Halara

Halara shot to fame in 2020 as a plus-size activewear brand through clever TikTok marketing. This newcomer used social media to reach body-diverse customers globally. This is different from traditional brands, which took decades to establish their presence.

Halara’s trendy plus size activewear

The brand offers plenty of plus size activewear choices from crossover leggings to 2-in-1 yoga shorts and active dresses. Their plus size collection features items like the “High Waisted Crossover Side Pocket Plain Plus Size Full Length Leggings” and the “Cloudful® Air High Waisted Drawstring Side Pocket Plain Full Length Plus Size Joggers.””

Halara’s product line now goes beyond simple activewear with work pants, casual jeans, and versatile overalls. Their products blend stylish designs with practical features such as:

• Hidden pockets and side storage in most styles
• High-waisted, tummy-control options
• Different lengths for various priorities (3″, 4″, 5″ shorts)

Halara’s affordable pricing and global reach

The brand stands out with budget-friendly prices. Their plus size collection costs between $34.95 and $74.95, with most items priced from $39.95 to $59.95. These prices make them a wallet-friendly option compared to premium activewear brands.

Halara started as an online-only store but opened their first pop-up in Manhattan in 2023. The soaring win led them to plan more pop-ups in Texas, California, and Florida. They’re also looking at international retail opportunities in Europe, Japan, and South Korea.

Halara’s fabric technology and comfort

Halara separates itself through unique fabric technologies that blend performance and comfort:

• Patitoff 2.0: Pet hair-resistant technology crafted for pet owners
• Softlyzero: Buttery-soft material that feels like a “second skin” – perfect for workouts and lounging
• Breezeful: Quick-dry fabric ideal for resort wear and active lifestyles
• Cloudful: Ultra-comfortable material suited for casual and athleisure styles

The brand makes use of information about fabrics to deliver premium features at lower costs than high-end competitors. This approach has made Halara a strong player in the growing plus size activewear market.

8. PopFlex Active

PopFlex Active, created by fitness influencer Cassey Ho of Blogilates, offers stylish plus-size activewear. It stands out from traditional designs. The brand shapes its identity through community input and trendy styles. This approach sets it apart from competitors that mainly focus on manufacturing.

PopFlex’s influencer-led design approach

The brand takes a unique customer-first approach through its POWERGIRLS program, which lets everyday women take part in product development. The company asks for feedback from women of all body types before they finalize their designs.

Taylor Swift was recently seen in their lilac skort. This got the brand a lot of attention. It shows how their influencer ties help increase visibility.

PopFlex’s plus size leggings and support features

The brand’s size range runs from XXS to 3XL across all their activewear collections. Their leggings come with smart design features that address what plus size customers need most:

• Anti-cameltoe technology that prevents unwanted exposure
• Squat-proof fabric that stays opaque during exercise
• Heart-shaped back seams that lift and flatter
• Length options from 23″ to 31″ for different heights
• Side pockets in most styles for convenience

The brand offers three waistband styles to suit different body shapes: Hourglass (with crisscross bands for an hourglass look), Supersculpt (for full body shaping), and Cargo (with drawstrings that prevent slipping).

PopFlex’s stylish and functional activewear

PopFlex stands out among plus size activewear brands by mixing performance with fashion-forward designs. Their antimicrobial fabrics stop bacteria growth while staying breathable. The moisture-wicking technology keeps you dry even during tough workouts.

Expert Insight: Users love how long PopFlex clothes last, with many saying “they make me feel strong and confident”. The brand is dedicated to innovation. It offers specialized legging lines like Contour, Supersculpt, Crisscross Hourglass®, Cargo, and Seamless collections.

Anna Lyly, Buying Manager

9. Juno Active

Juno Active, a 28-year-old company founded in 1995, is one of the oldest plus size activewear manufacturers. They have spent over 25 years making sportswear specifically for plus size bodies.

Juno Active’s mission to strengthen plus size women

Juno Active caters exclusively to plus size women and offers sizes from XL to 6X. They stand apart from other brands by building a community that understands plus size women’s unique challenges. Their support goes beyond just making clothes. The company launched a Plus-Size Events & Communities Page. This page helps active plus-size women meet fitness lovers who share their interests.

Juno Active’s high-tech fabrics and performance

Juno Active’s expertise in innovative performance fabrics makes them unique among plus size activewear manufacturers. Their signature technologies include:

• SoftWik® collection—ultra-soft, quick-drying fabrics available in tees, pants, and dresses
• QuikEnergy and AquaSport swimwear technologies for different swimming needs
• UPF 50 protection in their SunLite Collection

These high-tech fabrics last longer than typical fast-fashion activewear, which makes them cost-effective and eco-friendly. Each piece goes through extensive testing to ensure it works well during activities from gym workouts to swimming.

Juno Active’s sustainability and fit-first design

Unlike brands that just scale up standard sizes, Juno Active creates designs specifically for plus sizes. They emphasize: “We don’t design a size 6 sample and size it up for our plus sizes.” The company develops measurements and fittings using real plus-size women’s bodies.

Their designs address plus-size needs through features like chafe-reduction, better bust support, and heat management. The activewear easily shifts from workouts to casual wear. You can use it for yoga or everyday activities.

Recommended Reading: Best 10 Sportswear Manufacturers In China

10. Athleta

Athleta has established itself as one of the most socially responsible plus size activewear manufacturers since becoming a Certified B Corporation in 2018.

Athleta’s social and environmental responsibility

Athleta shows its environmental dedication through smart material choices. Their green fabrics include:

• Organic cotton grown without toxic chemicals
• Recycled nylon and polyester from plastic bottles and textile scraps
• TENCEL™ lyocell derived from wood pulp
• YULEX® Natural Rubber as an eco-friendly alternative

Athleta wants to cut GHG emissions by 90% in Scope 1 and 2, plus 30% in Scope 3 by 2030 compared to 2017 levels. The company has transformed over 441 million plastic bottles into recycled fabrics and kept 1,662 tons of textile waste out of landfills. They have also committed to remove problematic plastic packaging and source all cotton from sustainable sources by 2025.

Athleta’s plus size activewear range

The average American woman wears above a size 10. Recognizing this, Athleta expanded their sizing significantly in 2021 to include XXS to 3X in over 500 different styles. Their plus-size collection includes moisture-wicking technology and breathable mesh panels. It also has strategic seaming designed for curvy bodies.

The brand’s complete plus-size options include:

• Performance leggings with hidden pockets
• Moisture-wicking tanks and tees
• Sports bras designed for D-DD+ cup sizes
• Breathable joggers and pants

Conclusion

Plus-size activewear manufacturing has evolved beyond basic size scaling. Let’s take a closer look at how top manufacturers use specialized techniques. Universal Standard’s Fit Liberty program, Day Won’s antimicrobial fabrics, and Juno Active’s proprietary technologies developed over 25 years showcase this evolution. These breakthroughs show a steadfast dedication to serving different body types with both functionality and style.

A clear pattern emerges – the most successful manufacturers actively seek feedback from plus-size individuals instead of making assumptions about their needs. This customer-centered approach creates thoughtful features like strategic seam placement, improved support structures, and specialized compression levels.

You can reach us at leelineSourcing.com or [email protected] to discuss custom clothing needs or learn more about partnering with custom clothing manufacturers.

FAQs

1. Why are plus size activewear manufacturers important in 2025?

Plus size activewear manufacturers respond to the rising need for inclusive sportswear. They offer sizes up to 7XL. This promotes body positivity and supports healthy lifestyles for everyone.

2. What types of products do plus size activewear manufacturers offer?

They make leggings, sports bras, tank tops, hoodies, and joggers. Sizes range from XL to 7XL. Their products focus on comfort, performance, and style. Some items also have customizable options.

3. How do I find trusted plus size activewear manufacturers?

Check platforms like Alibaba or ThomasNet. Verify certifications such as OEKO-TEX and GRS. This helps ensure quality and inclusivity standards.

4. Are plus size activewear manufacturers cost-effective compared to standard sizes?

Costs are slightly higher due to extra fabric and specialized patterns (e.g., $15-$50 per item), but bulk orders and local sourcing (e.g., USA, China) reduce expenses.