How to avoid pilling and transparency issues in gym leggings?

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Pilling and transparency are two of the most common quality complaints in gym leggings. From a professional activewear manufacturer’s perspective, these issues are largely preventable through the right material choices, construction methods, and quality control processes. Below is a practical, experience-based breakdown.

1. Choose the Right Fabric Structure, Not Just Composition

Pilling is often caused by short fibers and low yarn strength, especially in low-grade polyester or cotton blends. For high-performance leggings, manufacturers should prioritize nylon–spandex blends with high filament yarns, which are smoother and more abrasion-resistant. At ohsurewear, we select fabrics tested specifically for anti-pilling performance under repeated friction.

2. Control Fabric Weight & Density to Prevent Transparency

Transparency usually results from fabric that is too lightweight or loosely knitted. While thin fabrics may feel soft, they often fail squat tests. A balanced GSM (typically 220–280gsm for leggings) combined with high stitch density ensures coverage without sacrificing stretch. ohsurewear conducts stretch-and-recovery testing to verify opacity under movement.

3. Optimize Knitting & Stretch Recovery

Poor knitting tension or uneven elastane distribution can cause fabric thinning when stretched, leading to see-through areas. Professional factories work closely with knitting mills to ensure consistent tension and four-way stretch recovery, especially for high-waist and hip zones.

4. Smart Pattern Design & Panel Placement

Transparency can also be a design issue. Overstretched panels, poorly placed seams, or single-layer areas at high-stress zones increase risk. Experienced manufacturers adjust pattern grading and use double-layer construction where needed, such as waistbands.

5. Enforce Testing & Bulk Quality Control

Lab testing (anti-pilling, abrasion, stretch opacity) should be completed before bulk production—not after. During production, in-line inspections and random squat tests help catch issues early. ohsurewear integrates these checks into every production stage.

Manufacturer Insight:

Avoiding pilling and transparency is not about one solution—it’s about fabric science, engineering design, and disciplined quality control. Partnering with a specialized manufacturer like ohsurewear ensures leggings perform well in real workouts and hold up in the market.

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How to avoid pilling and transparency issues in gym leggings?

Are you looking for a reliable fitness clothing manufacturer?

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product

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