Sew Your Own Activewear: The Fun, Fit, and Freedom of DIY Workout Clothes

Let’s be real—finding activewear that actually fits, feels good, and flatters? Not always a walk in the park (or on the treadmill). That’s why more and more people are grabbing their sewing machines and going full-on DIY with their workout clothes. Whether you're tired of see-through leggings, awkward seams, or just want your gym gear to scream you, sewing your own activewear might just be your new favourite project.

Why Make Your Own Workout Clothes?

• Fit Like a Glove: Say goodbye to saggy waistbands and too-tight tops. You control the measurements.

• Pick Your Performance: Choose breathable, moisture-wicking, or recycled fabrics based on your workout.

• Style Your Way: Leopard print yoga pants? Color-blocked sports bra? Go wild.

• Eco-Friendly Bonus: Reduce waste and fast fashion with sustainable sewing choices.

Pro Tips for Sewing Your Own Activewear

Before you dive into spandex paradise, here are a few must-know tips to help your DIY fitness gear turn out like a pro made it.

1. Choose the Right Fabric

Activewear needs stretch! Look for four-way stretch knits, like nylon-spandex or polyester-spandex blends. For breathability and performance, consider:

• High performance knits like our Athletic Solids

• Power mesh (for ventilation panels and extra support where needed). Perforated mesh is also great for ventilation, visual interest and breezy tops

• Recycled poly blends (hello, sustainable sewing!)

Pro tip: Always do a stretch test—pull the fabric both ways and make sure it snaps back easily.

2. Use the Right Needle & Thread

Swap out your universal needle for a ballpoint or stretch needle to avoid skipped stitches. Pair it with polyester thread—it’s stronger and more elastic-friendly than cotton.

And yes, a serger helps with clean seams—but don’t stress if you don’t have one. A zigzag stitch or stretch stitch on your sewing machine works just fine.

3. Pick Patterns That Move With You

Start with beginner-friendly patterns like:

• Leggings with a yoga waistband

• Racerback sports bras

• Fitted tanks or bike shorts

You can find digital sewing patterns online or use your favorite pair of leggings as a template (pro tip: trace before you cut!).

4. Test the Fit—Always!

Make a muslin (test version) using inexpensive stretch fabric before cutting into your fancy print. Test out squats, stretches, and dance moves to make sure seams hold and nothing rolls down where it shouldn't. 😉

5. Add Performance Features

Want to level up your DIY workout clothes? Try adding:

• Flatlock seams for comfort

• Hidden pockets for keys or cards

• Elastic waistbands with drawstrings

• Thumbholes in sleeves for that athleisure look

6. Unsure of what fabric to get?

Grab an Athletic Kit in Fat Half or Full Metre! You’ll get 3 fabrics (Solid, Power & Perforated  Mesh) in matching or complementary colours. No need to choose—you get all the options to get your creativity on!

Sewing Activewear Is Empowering (and Kinda Addictive)

Once you realize you can make a pair of leggings in a weekend that fit better than anything from the store, you’ll never go back. Plus, creating custom fitness clothes adds a boost of motivation to your workouts—because let’s face it, wearing something you made is a flex in itself.

Ready to Get Started?

Shop our curated collection of athletic fabrics, DIY athletic kits, and notions. Whether you’re starting small with a tank top or diving into full matching sets, we’ve got your back (and your backside).

✅ Final Stitch: Your Sewing Activewear Checklist

• ✅ Stretchy, breathable fabric

• ✅ Ballpoint/stretch needles

• ✅ Polyester thread

• ✅ Beginner-friendly pattern

• ✅ Confidence to make it your own

Start sewing your own activewear today—and never settle for boring workout clothes again.