Athletic fabric is specifically designed for active lifestyles, engineered to wick away moisture, provide excellent stretch and recovery, and keep you comfortable during exercise. Whether you're sewing leggings, sports bras, running shorts, or yoga wear, athletic knits deliver the performance and durability you need.
Made from synthetic materials like polyester spandex or nylon spandex, athletic fabrics offer moisture-wicking properties, quick drying, and excellent 4-way stretch that moves with your body. Many of our athletic fabrics feature UV protection, making them perfect for outdoor activities.
What is Athletic Fabric?
Athletic fabric is a performance knit fabric specifically engineered for exercise and active wear. Unlike regular cotton knits, athletic fabrics are made from synthetic materials (primarily polyester spandex or nylon spandex blends) that wick moisture away from your skin, dry quickly, and provide exceptional stretch and recovery.
The key difference between athletic fabric and everyday knits is the fabric's technical performance. Athletic knits are designed to pull sweat away from your body to the fabric's surface where it can evaporate, keeping you dry and comfortable during workouts. The 4-way stretch allows unrestricted movement, while the excellent recovery ensures the fabric snaps back to its original shape rather than sagging or bagging out.
Why Choose Athletic Fabric?
- Moisture Wicking - Pulls sweat away from skin to keep you dry
- 4-Way Stretch - Moves with your body in all directions
- Excellent Recovery - Returns to original shape after stretching
- Quick Drying - Dries much faster than cotton-based fabrics
- No Shrinkage - Synthetic materials don't shrink when washed
- UV Protection - Many fabrics rated UV 50+ for sun protection
- Breathable - Allows air circulation during exercise
- Durable - Withstands numerous washings while maintaining performance
- Forgiving Fit - Great stretch makes sewing more forgiving
- Non-Curling Edges - Edges don't curl like cotton lycra
- Flattering - Compression and stretch create sleek silhouettes
- Lightweight Options - Available in various weights for different activities
Types of Athletic Fabric
We carry several different types of athletic fabric, each with unique characteristics for different projects:
Athletic Knit
Our standard athletic knit is the workhorse of performance fabrics. Made from polyester/spandex blends (typically 85% polyester, 15% spandex), it offers excellent moisture wicking, 4-way stretch, and recovery. Perfect for: leggings, yoga pants, running tops, sports bras, athletic shorts, gym wear, leotards, and all fitted activewear.
Honeycomb Athletic Knit
Same performance qualities as regular athletic knit but with a trendy textured honeycomb surface that adds visual interest. The textured surface provides extra breathability and a modern athletic look. Perfect for: leggings, athletic tops, sports bras, yoga wear, and anywhere you want texture.
Premium Athletic Knit
Higher-end athletic knit with superior hand feel and performance. Often features enhanced moisture wicking, better recovery, or special finishes. Perfect for: high-performance athletic wear, competitive sports apparel, yoga wear.
Endurance Eco Athletic Knit
Made from Repreve® recycled polyester manufactured from recycled water bottles - stay fit and help save the planet! Features moisture wicking and UV protection. Perfect for: eco-conscious athletic wear, leggings, athletic tops, dance wear.
Nylon Spandex
Premium athletic fabric with a smooth, cool hand. Nylon spandex is typically softer and silkier than polyester versions. Many feature UV 50+ protection. Perfect for: swimwear, yoga pants, leggings, tops, leotards, sports bras, dance wear, and fitted activewear.
Swim & Sport
Dual-purpose fabric with smooth hand and 4-way stretch that works for both swimwear and athletics. Designed to move with your body and dry quickly. Many feature UV 50+ protection. Perfect for: swimwear, rash guards, athletic wear, dance, gymnastics, paddle sports, and water activities.
What Can You Make with Athletic Fabric?
Athletic fabric is incredibly versatile for active wear and beyond:
- Leggings and yoga pants
- Running shorts and athletic shorts
- Sports bras and athletic bralettes
- Tank tops and running tops
- Fitted athletic t-shirts
- Bike shorts and compression shorts
- Yoga tops and pullovers
- Athletic skirts and tennis skirts
- Dance wear and leotards
- Gymnastics apparel
- Rash guards and swim shirts
- Athletic dresses
- Activewear sets and matching sets
- Paddle sports apparel
- Cycling gear
Looking for athletic sewing patterns? Check out these popular patterns from Peek-a-Boo Pattern Shop:
- Momentum Shorts - 2-in-1 athletic shorts with multiple options
- Leggings patterns - Perfect for athletic knits
- Sports bra patterns - Essential activewear staples
Frequently Asked Questions About Athletic Fabric
What's the difference between athletic fabric and regular cotton lycra?
Athletic fabric is made from synthetic materials (polyester or nylon with spandex) specifically engineered for moisture wicking and quick drying. Cotton lycra absorbs moisture and takes longer to dry. Athletic fabric is ideal for exercise because it pulls sweat away from your body, while cotton lycra holds moisture against your skin. Athletic fabric also has better recovery and doesn't shrink.
Does athletic fabric shrink when washed?
No, athletic fabric does not shrink because it's made from synthetic materials (polyester or nylon) rather than natural fibers. However, we still recommend pre-washing before starting your project to remove any manufacturing chemicals or finishes. Always wash cold and tumble dry low to maintain fabric integrity.
What needles and thread should I use for athletic fabric?
Use stretch or ballpoint needles (size 75/11 or 80/12) to prevent damage to the knit structure. Regular polyester thread works perfectly - you don't need special thread. Use a stretch stitch, zigzag, or serger/overlock stitch to allow seams to stretch with the fabric.
Can I use athletic fabric for everyday wear, not just exercise?
Absolutely! Athletic fabric makes comfortable, durable everyday wear. Many people use it for leggings, casual tops, lounge wear, and travel clothing because of the comfort, stretch, and wrinkle-resistance. It's especially great for travel since it dries quickly and doesn't require ironing.
What's the difference between athletic knit and nylon spandex?
Athletic knit is typically polyester/spandex blend with a slightly matte finish and good structure. Nylon spandex has a smoother, silkier hand with more sheen and drape. Nylon spandex is often used for both athletic wear and swimwear, while athletic knit is primarily for exercise apparel. Both have excellent moisture wicking and 4-way stretch.
Does athletic fabric need to be pre-washed?
While athletic fabric doesn't shrink, we recommend pre-washing to remove any manufacturing finishes or chemicals. Pre-washing also allows the fabric to relax before cutting. Wash cold and tumble dry low, just as you would finished garments.
Can I sew athletic fabric on a regular sewing machine?
Yes! You can absolutely sew athletic fabric on a regular sewing machine. Use a stretch or ballpoint needle and a zigzag stitch or stretch stitch. A serger/overlock machine gives the most professional finish but isn't required. Many sewists make beautiful athletic wear with just a basic sewing machine.
What's the advantage of UV-rated athletic fabric?
UV-rated athletic fabrics (typically UV 50+) provide sun protection, blocking harmful UV rays from reaching your skin. This is especially important for outdoor activities like running, hiking, paddle sports, and water activities where you're exposed to sun for extended periods. UV protection is built into the fabric and doesn't wash out.
How do I prevent athletic fabric from curling at the edges?
Athletic fabric typically curls much less than cotton lycra! This is one of the benefits of the synthetic fiber content. If you do experience curling, press lightly with a low-temperature iron (synthetics can melt with high heat), or serge/overlock edges immediately after cutting.
Can athletic fabric be used for swimwear?
Some athletic fabrics, particularly nylon spandex and fabrics labeled "Swim & Sport," work beautifully for swimwear. However, not all athletic fabrics are suitable for chlorine and saltwater exposure. Look for fabrics specifically labeled for swim use or check the UV rating - UV 50+ fabrics are typically swim-appropriate. For serious swimmers or frequent chlorine exposure, choose dedicated swim fabric.
Tips for Sewing with Athletic Fabric
- Use stretch needles - Size 75/11 or 80/12 ballpoint/stretch needles prevent skipped stitches
- Choose stretch stitches - Zigzag, stretch stitch, or serger/overlock allows seams to stretch
- Regular thread works fine - Standard polyester thread is perfect; no special thread needed
- Lower iron temperature - Synthetics melt with high heat! Keep iron on low setting
- Pre-wash recommended - Removes finishes and allows fabric to relax before cutting
- Use clips instead of pins - Prevents permanent pin holes in synthetic fabrics
- Test on scraps first - Check needle, thread, and stitch settings before starting
- Don't stretch while sewing - Let fabric feed naturally under presser foot
- Serger gives best results - But regular machine with zigzag works well too
- Consider clear elastic for support - Stabilizes waistbands and necklines
- Press with low heat - Use pressing cloth to protect fabric from melting
- Edges don't curl as much - One of the benefits compared to cotton lycra!
Making Bias Binding from Athletic Fabric
Athletic fabric makes excellent bias binding or trim for finishing athletic shorts, sports bras, and other activewear. Here's the process:
- Cut your trim piece - Cut on the bias (45-degree angle) or crossgrain for maximum stretch
- Fold in half lengthwise - Wrong sides together, press flat with LOW heat (synthetics melt!)
- Fold raw edges to center - Bring both raw edges to meet at the center fold line, press flat
- Fold in half again - Your trim should now be folded in quarters with raw edges enclosed in the middle
Application tip: Stretch woven athletic fabric holds crisp folds better than knit athletic fabric for binding. Nylon spandex can be trickier to fold - take your time establishing good creases.
To attach binding: Unfold the trim and pin/clip the right side of trim to the wrong side of garment. Sew along the first fold line. Refold the trim around the raw edge, covering your stitching. Topstitch from the right side to secure.
Athletic Fabric Care Instructions
- Wash cold - Preserves elasticity and color
- Tumble dry low - Or lay flat to dry
- Wash inside out - Protects surface from friction
- Avoid fabric softener - Can reduce moisture-wicking properties
- Don't wash with rough items - Towels, jeans can cause pilling
- Separate lights and darks - Especially for first few washes
- No bleach - Can damage synthetic fibers
- No high heat - Synthetic fibers can melt or lose elasticity
Good news: Athletic fabric withstands numerous washings while maintaining its performance properties and looking brand new! It's much more durable than cotton-based fabrics.
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Why Buy Athletic Fabric from KnitFabric.com?
- Fast Shipping: Flat rate shipping on all orders
- UV Protection: Many fabrics rated UV 50+ for outdoor activities
- Eco-Friendly Options: Endurance Eco fabrics made from recycled materials
- Quality Performance: Moisture wicking, quick-dry, excellent recovery
- Wide Selection: Solids, prints, camos, and specialty finishes
- Multiple Brands: Knit Basics, Euro Imports, and more
- Expert Support: Our team knows activewear sewing inside and out
- Perfect for All Activities: Running, yoga, gym, dance, water sports, and more
Shop our full collection of athletic fabric by the yard and create high-performance activewear that keeps you comfortable during any activity!
Questions about which athletic fabric to choose or how to sew activewear? Contact us—we're here to help!