Short answer: Activewear unit cost is shaped by fabric, construction, quantity, colorways, size range, logo method, labels, packaging, QC expectations, payment terms and shipping assumptions. A cheaper quote is not always cheaper if key items are excluded.
Main cost drivers
| Cost driver | What changes price | Buyer note |
|---|---|---|
| Fabric | Composition, GSM, stretch, compression, opacity, color and availability | Custom fabric or custom color usually raises MOQ and lead time |
| Construction | Seamless, cut-and-sew, padding, lining, pockets, special seams | Sports bras and fitted leggings need more fit review |
| Quantity | Pieces per style and color | 200+ pcs per style is often a stronger first bulk base |
| Colors | Number of colorways and whether fabric is stock or dyed | Too many colors can make a first order inefficient |
| Size range | Number of sizes, grading and size ratio | More sizes add complexity and inventory risk |
| Branding | Logo method, label, care label, hang tag and placement | Confirm what is included in the quoted price |
| Packaging | Polybag, zipper bag, barcode, size sticker, carton marks | Retail packaging should be locked before bulk packing |
| QC and shipping | Inspection, packing evidence, cartons, delivery term and destination | EXW, FOB and DDP quotes are not directly comparable |
What a quote should clarify
Before comparing suppliers, ask whether the quote includes garment only or also logo, labels, packaging, inspection, shipping, duties or documentation. Many misunderstandings happen because two quotes look similar but include different assumptions.
- Is the fabric stock, custom color or custom developed?
- Is the price per style, per color or total order quantity?
- Are logo, labels and packaging included?
- Is sample cost separate from bulk cost?
- Is shipping EXW, FOB, DDP or not included?
- When is the balance payment due, and what evidence is reviewed first?
Cost planning by quantity range
| Quantity route | Cost behavior | Best use |
|---|---|---|
| Under 100 pcs | Often sample, stock or very limited route | Product validation, not full private label planning |
| 100-199 pcs | Possible if simplified | Few styles, fewer colors, standard packaging |
| 200+ pcs per style | Better first bulk review | Focused private label launch with clearer branding and QC |
| 500+ pcs per style | More room for customization | Deeper fabric, color and packaging decisions |
Why cheapest is not always best
A low unit price can exclude packaging, labels, inspection, shipping evidence or realistic fabric assumptions. For first orders, buyers should compare total landed assumptions and approval steps, not just garment unit price.
How to reduce cost without weakening the order
- Limit the first launch to one to three core styles.
- Use fewer colorways until sales feedback is clear.
- Use available fabric routes when possible.
- Keep branding simple for the first bulk order.
- Confirm size ratio early to avoid inefficient cutting and inventory risk.
- Lock packaging before production packing starts.
Related planning pages
FAQ
What affects activewear bulk order cost most?
Fabric, quantity, construction, colors, size range, branding, packaging, QC and shipping assumptions usually affect cost most.
Is 200+ pcs cheaper than 100 pcs?
Often the unit cost is more practical around 200+ pcs per style because fixed setup, branding, packaging and production planning are spread across more units.
Should I compare EXW and DDP prices directly?
No. EXW, FOB and DDP include different responsibilities. Compare quotes only after shipping and duty assumptions are clear.