How to Choose the Right Fabric GSM for Activewear?

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Accepted Answer

Fabric GSM (grams per square meter) directly affects opacity, support, breathability, durability, and overall wear performance in activewear.

Based on 15+ years of activewear manufacturing experience at Ohsurewear, choosing the right GSM is not about “heavier is better,” but about matching fabric weight to function, movement, and brand positioning.

Below is a practical, factory-level guide used in real OEM & ODM production.

1️⃣ What Does GSM Mean in Activewear Manufacturing?

GSM measures fabric weight per square meter. In activewear, GSM influences:

• Thickness and coverage (squat-proof level)

• Compression and support

• Heat retention vs breathability

• Fabric durability over repeated wear and washing

From a manufacturer’s perspective, GSM must always be evaluated together with fiber composition and knit structure, not in isolation.

2️⃣ Low GSM Fabrics (160–200 GSM)

Best for: Light-support tops & breathable layers

Common applications

• Lightweight sports bras (low impact)

• Yoga tops and tanks

• Summer training wear

Characteristics

• High breathability

• Lightweight and flexible feel

• Faster drying

Limitations

• Limited compression

• Not suitable for squat-proof leggings

At Ohsurewear, low GSM fabrics are typically used for upper-body activewear, not bottoms.

3️⃣ Medium GSM Fabrics (210–250 GSM)

Best for: Everyday leggings & mid-support sports bras

This is the most versatile GSM range in bulk activewear production.

Common applications

• Yoga and gym leggings

• Medium-support sports bras

• All-season activewear sets

Why this range works

• Balanced stretch and support

• Improved opacity for leggings

• Comfortable for long wear

Most core leggings at Ohsurewear are developed within this GSM range for commercial-ready performance.

4️⃣ High GSM Fabrics (260–320 GSM)

Best for: Compression leggings & high-impact sports bras

High GSM fabrics are used when support and structure are the priority.

Common applications

• High-compression leggings

• Running or HIIT sports bras

• Sculpting or shaping collections

Key benefits

• Enhanced compression and muscle support

• Superior squat-proof performance

• Better shape retention over time

Trade-offs

• Reduced breathability

• Heavier hand feel

This GSM range is commonly paired with nylon/polyamide + Lycra blends in premium collections at Ohsurewear.

5️⃣ GSM Alone Is Not Enough — Construction Matters

From a professional manufacturing standpoint, GSM must be considered alongside:

• Fiber composition (nylon vs polyester)

• Knit type (single jersey, interlock, double-knit)

• Yarn quality and elastane ratio

• Finishing processes (brushed, sanded, compacted)

A well-constructed 230 GSM double-knit fabric can outperform a poorly made 280 GSM fabric.

6️⃣ Choosing GSM Based on Activity Type

Activity Type	Recommended GSM
Yoga / Pilates	210–230 GSM
Gym Training	220–250 GSM
Running / HIIT	240–300 GSM
Lifestyle / Athleisure	200–230 GSM
At Ohsurewear, GSM selection always starts with end-use analysis, not price alone.

Manufacturer Insight from Ohsurewear

One of the most common mistakes brands make is over-specifying GSM in hopes of better quality. In reality, excessive GSM can compromise comfort, flexibility, and wearability.

Professional activewear development focuses on:

• Functional performance

• Long-term durability

• Consistent bulk production results

That’s why Ohsurewear evaluates GSM together with fabric structure, stretch recovery, and real wear testing before final approval.

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