How to Create an Activewear Tech Pack (And What to Do If You Don’t Have One)

The answer is the Tech Pack.

As a premium custom activewear manufacturer, Wensfashion reviews hundreds of design inquiries every month. The most common mistake new brand owners make is sending a screenshot from Instagram or Pinterest and asking, “Can you make this?” While we can use photos for inspiration, true custom manufacturing requires precise data.

Here is our ultimate B2B guide on what goes into a professional activewear Tech Pack, why it saves you money, and how we can help if you don't have one.

A Tech Pack (Technical Package) is an informative document created by a designer to communicate with a manufacturer. Think of it as an architectural blueprint for a house, but for clothing. It tells the factory exactly how to construct the garment, what materials to use, and how it should fit.

A well-crafted Tech Pack eliminates guesswork, speeds up the sampling process, and prevents expensive miscommunications.

A sketch is not a fashion illustration of a model; it is a 2D black-and-white “flat” drawing of the garment.

It must show the front, back, and side views.

It must include Callouts (arrows pointing to specific details like hidden zipper pockets, asymmetrical straps, or seamless ribbed zones).

Factory Tip: For athleisure, showing the exact placement of the crotch gusset (to prevent camel toe) or the back yoke (for glute contouring) is critical.

The BOM is the recipe for your garment. It lists every single physical component required to make one complete unit.

Main Fabric: e.g., 75% Nylon / 25% Spandex, 240 GSM, Double-sided brushed.

Trims & Hardware: YKK zippers, drawstrings, elastic bands, bra pads.

Labels: Heat-transfer neck labels, woven hem tags, hangtags, and polybags.

Activewear undergoes extreme stress during workouts. Your Tech Pack must specify the type of seams used.

Will you use standard overlock stitching, or premium 4-needle 6-thread Flatlock stitching to prevent chafing?

What is the thread tension required for high-stretch areas?

Leaving this blank means the factory will choose the cheapest, fastest option.

You cannot just say “Make it Sage Green.” You must provide the exact Pantone (TPX/TCX) color codes.

If your design includes a printed pattern (like camouflage or a gradient ombre), you must attach a high-resolution, seamless vector file and specify the printing method (e.g., Sublimation or Screen Printing).

This is the most mathematical part of the Tech Pack. It provides the exact dimensions (in inches or cm) for your base size (usually a Medium).

It lists the waist width, inseam length, chest circumference, and strap lengths.

Eventually, this sheet will include “Grading Rules”—the mathematical formula that dictates how the garment scales up to a Large or down to a Small.

Creating a professional Tech Pack requires expensive software (Adobe Illustrator) and years of technical fashion design experience. Hiring a freelance activewear designer to make just one Tech Pack can cost between $150 and $500.

This is where Wensfashion changes the game.

We understand that many brand owners are brilliant marketers and visionaries, but not technical designers. To bridge this gap, we offer comprehensive ODM (Original Design Manufacturing) and R&D services.

If you don't have a Tech Pack, you have two highly profitable options with us:

The gap between a good idea and a best-selling activewear brand is a flawless technical execution. Whether you have a fully finalized Tech Pack ready for production, or just a vision that needs expert development, Wensfashion is your premium manufacturing partner.