Thinking about sewing your own activewear? Maybe you've got a leggings pattern saved or you've been wanting to make a comfy sports bra that actually fits. Either way, athletic knit fabric is a great place to start learning about the materials you'll need.

Athletic knit is a popular choice for workout clothes because of its stretch and flexibility. Many varieties also have moisture-wicking properties, making them especially useful for clothing you plan to move around in. Of course, choosing the right type matters, and sewing stretchy fabrics can take a little practice.

Don't worry, though! We'll break down the different types of athletic knit fabric, what you can make with them, and some simple tips to make sewing a little easier.

What Is Athletic Knit Fabric?

Athletic knit fabric is a type of stretchy fabric designed for activewear, sportswear, and everyday athleisure clothing. It's made using interlocking loops of yarn that allow the fabric to stretch and move with your body. Unlike woven fabrics, which generally have less natural stretch, athletic knits offer greater flexibility, making them a popular choice for comfortable, fitted clothing.

Most athletic knit fabrics are made from polyester or nylon blended with spandex (also called elastane). Depending on the blend and knit construction, they can offer four-way stretch, moisture-wicking properties, breathability, and good stretch recovery. These qualities make them especially useful for clothing that needs to move comfortably while keeping its shape.

For home sewists, athletic knit fabric is a great option for making leggings, yoga pants, sports bras, workout tops, and athletic skirts and skorts. You can also use it for casual everyday pieces that need a little extra stretch. Just keep in mind that not all athletic knits perform the same way, so it's worth checking the fabric's stretch and feel before choosing one for your project.

Shop Fabric + Flow’s Athletic Knit Fabric Collection →

Key Properties and Benefits of Athletic Knit Fabric

From comfortable stretch to moisture management, athletic knits have several qualities that make them great for workout clothes and everyday wear.

Four-Way Stretch and Flexibility

Athletic knit fabric can have two-way stretch (across the width) or four-way stretch (across both the width and length). Four-way stretch allows greater freedom of movement, making it ideal for leggings and fitted activewear. Many spandex blends also offer good stretch recovery, helping garments keep their shape after repeated wear.

Moisture-Wicking and Quick-Drying Performance

Many moisture-wicking fabrics are constructed to move sweat away from your skin, helping you stay comfortable during workouts.

Fabrics made with polyester or nylon often dry faster than cotton, but moisture management depends on the fibre blend, knit construction, and fabric finishes. Some athletic knits simply handle sweat better than others, so it's worth checking their performance features before sewing.

Breathability and Temperature Regulation

Breathability helps heat and moisture escape, keeping you comfortable during workouts. Lightweight athletic knits and mesh fabrics allow better air circulation, making them great for running tops and warm-weather activewear. Denser knits offer more coverage and support but may trap more heat, so consider the fabric's weight and construction when choosing one for your project.

Stretch Recovery, Compression, and Shape Retention

Good stretch recovery helps athletic knit fabric return to its original shape instead of sagging after repeated wear. Spandex blends are especially useful for shape retention, keeping fitted garments like leggings snug and comfortable. Compression knits offer firmer muscle support, but the level of compression depends on the fabric's stretch resistance, knit construction, and garment fit.

Common Types of Athletic Knit Fabrics

Now that you know what makes athletic knit fabric great for activewear, let's look at the different types you can sew with!

Jersey Knit Fabric

Jersey knit fabric is a lightweight, flexible fabric with a smooth front and a slightly textured back. Its single-knit construction gives it a soft feel and comfortable stretch, making it great for workout shirts, tank tops, and relaxed sportswear. One thing to keep in mind when sewing a jersey is that its cut edges tend to curl, so you may need to take extra care when handling the fabric.

For soft, easy-to-wear projects, explore Fabric + Flow's Jersey Collection. It's a great place to find jersey fabrics for casual yoga tops and comfortable everyday basics. Just check the fibre content and stretch properties if you're sewing something for more intense workouts.

Shop Fabric + Flow's Jersey Knit Fabrics →

Interlock Knit Fabric

Interlock knit fabric has a double-knit construction that makes it thicker and more stable than single jersey, with a smooth finish on both sides. Its added structure and good shape retention make it a great choice for fitted workout tops and activewear that needs extra coverage.

Athletic Mesh Knit Fabric

Athletic mesh knit fabric has an open-knit construction that allows better air circulation, helping sweat evaporate and body heat escape during workouts. Its lightweight, breathable feel makes it a popular choice for sports jerseys and ventilation panels in athletic wear.

Looking for mesh fabrics for your next activewear project? Explore Fabric + Flow's AirMesh + PowerMesh Collection. Studio AirMesh is designed for breathability and ventilation, making it great for workout tops and breathable panels. PowerMesh, on the other hand, is a stretch mesh commonly used for supportive linings and areas that need extra stability, such as sports bras.

Shop Fabric + Flow's AirMesh + PowerMesh Collection →

Rib Knit and Compression Knit Fabrics

Rib knit fabric has a textured surface with raised vertical lines, giving it good stretch and flexibility. It's great for waistbands and fitted tops that need to stretch comfortably.

Compression knits, on the other hand, use denser constructions and strong spandex blends to create a firmer fit, providing muscle support and shape retention for leggings, sports bras, and other fitted activewear.

What Is Athletic Knit Fabric Used For?

Athletic knits are great for all kinds of activewear sewing projects. The key is choosing a fabric with the right stretch and support for what you're making. Here are some popular options:

Leggings and Yoga Pants

Leggings and yoga pants need athletic knit fabric with four-way stretch so you can bend and move comfortably. Medium-weight knits and compression knits with spandex are great choices because they offer good stretch recovery and shape retention. Look for fabrics with enough coverage to prevent them from becoming see-through when stretched.

Want to sew your own pair? Start with Fabric + Flow's Flow Leggings Pattern. Pair it with a four-way stretch athletic knit legging fabric for a comfortable, fitted activewear that moves with you.

Shop Fabric + Flow's Flow Leggings Pattern →

Athletic Skorts and Shorts

Athletic skorts and shorts are great projects for lightweight or medium-weight athletic knit fabrics that offer comfortable stretch and breathability. Look for four-way stretch and good recovery, especially for fitted shorts or built-in liners that need to stay in place while you move.

For a fun and practical sewing project, try Fabric + Flow's Drift Skort Pattern. With built-in fitted shorts, handy pockets, and a flowy skirt back, this skort pattern is a lovely choice for tennis, casual walks, or everyday wear.

Shop Fabric + Flow's Drift Skort Pattern →

Sports Bras and Fitted Workout Tops

Sports bras need a little more planning when it comes to activewear fabric choice, especially if you're a sewing sports bra for higher-impact workouts. Nylon-spandex blends and other athletic performance knits offer the flexibility needed for a close fit, while firmer compression fabrics can provide additional support.

Keep in mind that the athletic fabric is only part of the construction. You'll also need the right elastic and lining to help the bra stay secure and provide adequate coverage during movement.

If this is your first time sewing one, we highly recommend that you work with a sports bra pattern, like Fabric + Flow's Flow Bra Pattern. Pair it with a four-way stretch athletic knit and the recommended support materials to create a comfortable, fitted sports bra for your workout wardrobe.

Shop Fabric + Flow's Flow Bra Pattern →

Running Shirts, Tank Tops, and Lightweight Activewear

For running shirts and tank tops, lightweight fabrics like polyester performance jerseys are great for keeping you cool without adding extra bulk. Look for moisture-wicking properties to help manage sweat, or try breathable mesh knits for better airflow during workouts. Just remember that thinner fabrics may offer less coverage, so check the fabric's opacity before sewing.

Tips for Sewing Athletic Knit Fabric at Home

Athletic knit fabric can be a little tricky to sew, especially when it stretches, shifts, or puckers under your machine. But a few simple techniques can make all the difference in creating smooth seams and comfortable, long-lasting activewear.

Choose the Right Activewear Sewing Needle and Thread

When sewing athletic knit fabric, use stretch needles or ballpoint needles to help prevent skipped stitches and fabric damage. Stretch needles are especially useful for high-spandex blends, while ballpoint needles work well with many other knit fabrics. Pair your needle with a good-quality polyester thread that can handle the movement of stretch seams.

Use Stretch-Friendly Stitches and Seams

Since athletic knit fabric stretches as you move, your seams need enough flexibility to prevent stitches from popping. A narrow zigzag or lightning stitch works well on a regular sewing machine, while a serger is another great option for sewing stretchy seams.

Before sewing your athletic wear, test your stitch settings on a fabric scrap to make sure the seams can stretch comfortably without breaking.

Prevent Wavy Seams and Fabric Stretching

Athletic knit fabrics can stretch out of shape while sewing, leaving you with wavy or uneven seams. To prevent this, try using a walking foot to feed the fabric evenly and adjust your presser-foot pressure if needed.

If you're using a serger, adjusting the differential feed can also help reduce stretching. Most importantly, avoid pulling the fabric as you sew, and always test your settings on a scrap piece first.

FAQs about Athletic Knit Fabrics

How is athletic knit fabric different from regular knit fabric?

The main difference is how they're designed to perform. Regular knit fabrics, like cotton jerseys, are generally made for comfort and everyday clothing. Athletic knit fabrics are designed for activewear, often using polyester, nylon, and spandex blends to provide better stretch recovery and moisture management. They're especially useful for workout clothes that need to handle frequent movement.

What is the best activewear fabric for athletic wear?

It depends on what you're making! Polyester-spandex and nylon-spandex blends are popular choices because they offer comfortable stretch and good shape retention. For leggings and sports bras, look for four-way stretch fabrics with reliable recovery and enough coverage. For running shirts and lightweight workout tops, breathable, moisture wicking fabrics are often a better choice.

Can you sew athletic knit fabric without a serger?

Absolutely! You can sew athletic knit fabric using a regular sewing machine. A narrow zigzag or lightning stitch allows the seams to stretch with the fabric, helping prevent broken threads. Pair these stitches with a stretch or ballpoint needle, and avoid pulling the fabric as you sew. A serger is helpful for finishing seams, but you don't need one to make your own activewear.

What stretch percentage is best for athletic knit fabric?

The ideal stretch percentage depends on what you're sewing. Fitted activewear like leggings and sports bras often requires 50% or more stretch, while relaxed workout tops may need less. Always check your sewing pattern's stretch requirements before buying fabric.

Your Next Activewear Project Starts at Fabric + Flow!

You've learned about athletic knit fabrics, so now comes the fun part: picking out the fabric for your next sewing project! Whether you're making leggings for the gym or a comfy sports bra, Fabric + Flow has athletic knit fabrics to help bring your ideas to life.

Explore our Studio Collection for comfortable, flexible everyday activewear, or try our Sculpt CoreFlex and Sculpt MoveSoft fabrics for a firmer, higher-compression fit. You'll find different finishes and colours to suit your sewing plans, plus athletic wear patterns to help you get started.

Shop Fabric + Flow's Athletic Knit Fabrics →