The Definitive Guide to Manufacturing Custom Plus-Size Activewear

The activewear industry is finally embracing inclusivity, and the demand for high-quality, fashionable, and well-fitting plus-size activewear has never been higher. For apparel brands, this represents a significant and underserved market. However, creating a successful plus-size line requires more than just scaling up standard sizes; it requires a manufacturing partner with specialized expertise.

At KAIHON, we have years of experience as a leading athleisure manufacturer, partnering with top brands around the world. We specialize in creating custom plus-size activewear that delivers on performance, style, and—most importantly—fit. This guide will walk you through the critical steps of developing a successful plus-size line and how to vet a manufacturer to bring it to life.

The Key to Success: A Deep Understanding of Plus-Size Fit

Manufacturing for the plus-size market is a technical specialty. It requires a different approach to design, patterning, and grading than standard sizing.