Contents

How to Start Selling Activewear Online?
Best Print-on-Demand Activewear Products to Sell in 2025
Is Activewear Business Profitable?
Launch Your Activewear Brand
FAQs

In recent years, the demand for activewear has skyrocketed. This has made gym clothing popular in everyday fashion. From leggings, bras, to hoodies, polos, and sweatshirts, activewear has become a must-have item in everyone’s wardrobe around the world.

For print-on-demand (POD) sellers, athleisure presents a golden opportunity. It’s fashionable, functional, and in demand, making it the perfect year-round product category. Moreover, POD allows you to launch your own athleisure brand without investing in inventory, while offering unique, personalized designs that stand out in a crowded marketplace.

In this guide, we’ll walk you through a step-by-step guide for selling activewear online that’s easy for even beginners to follow.

No further ado, let’s explore the whole article below to get all the details!

How to Start Selling Activewear Online?

Starting an activewear apparel business can be difficult at first, but start small. You’ll be surprised at how much you can handle the journey.

Step 1: Research the Activewear Market & Choose Your Niche

Like any new venture, a successful activewear brand starts with thorough research. Before launching your brand, you need to analyze the market to determine what’s trending, what your competitors are offering, and what consumers want.

Consider these facts:

36% of active gym members are Millennials, a demographic that prioritizes workout wear that’s both stylish and comfortable.
42% of members come from small boutique gyms, proving that consumers are willing to pay for high-quality, custom-made workout wear that fits their workout routine.
The athleisure and streetwear trends are booming, driving demand for versatile gym wear that can be worn from the gym to the street without looking out of place.
Eco-conscious consumers are looking for sustainable activewear, made from recycled or organic materials – a potential segment worth tapping into.

Also, don’t overlook these market numbers: the average American spends $20–100 per month on a gym membership, and most believe that working out in a class is more effective than alone. That means they need workout clothes that are both comfortable and professional.

To find your niche, use tools like Google Trends, Instagram, or analyze your competitors’ strategies. This will help you identify untapped gaps, such as sustainable or plus-size activewear – fast-growing segments.

Once you’ve identified your niche, everything else, from product selection to brand messaging to pricing strategy, will be clearer and easier to implement. Think of this as the first step to building a standout activewear brand. And when you start launching a product, always ask yourself: “Does this product really meet the needs of the target customers?” If the answer is yes, you are on the right track; if unsure, go back to research and adjust your strategy.

Step 2: Select the Best Activewear Products to Sell

Once you have a clear understanding of your activewear brand, the next step is to choose a product group that fits the needs and lifestyle of your target customers.

Rather than thinking about a few specific clothing styles, you should look at the overall picture of each product group. Each group has its own business opportunities and market potential.

Sportswear products

Sportswear is aimed at consumers who live and breathe sports from the gym to the tennis court, to the beach. With the global sports industry expected to continue to grow at a rapid pace, this is a potential segment for brands that want to associate themselves with performance, functionality, and durability. Finding a specific niche (e.g., water sports, outdoor sports, or professional sports) can help your brand stand out and be remembered.

Athleisure products

When building your store, focus on products that align with the growing athleisure demand. Popular choices include tank tops, sports bras, leggings, biker shorts, and yoga pants. These items are versatile, stylish, and suitable for both fitness and casual wear, making them customer favorites in the online marketplace.

Streetwear products

Streetwear is one of the clearest proofs that activewear can become a fashion statement. Inspired by street culture, music, and retro fashion, this segment is especially favored by young people who are willing to spend a lot. The year-round wearability and diverse combination ability make streetwear a “golden goose" if your brand knows how to make its mark.

Plus-size Activewear

Increasingly, consumers are demanding brands that cater to all sizes and body types. Plus-size activewear is no longer a sub-category, but a mainstream trend, growing rapidly thanks to its combination of fashion, confidence, and functionality. It’s a segment that many big brands are investing heavily in, but the market is still large enough for newcomers to find a place.

Step 3: Find Activewear Suppliers (Bulk vs Print-on-Demand)

At this point, you may be asking yourself, “I have a business idea, but where do I get products to sell?” The answer is that you have two main paths to choose from, and each has its own pros & cons.

Buy in bulk from a manufacturer or distributor

This is the traditional way to build a true sportswear brand and have complete control over materials and design.

Benefits:

Freedom to develop your own collection.
Consistent product quality and experience.
Higher profit margins when the scale is large enough.

Challenges:

Large initial investment (inventory, factory, logistics).
High risk if the product does not sell.
Slower time to market.

This form is suitable for businesses with strong capital, experience in production/design, and willing to accept risks in exchange for high profits.

Use Print on Demand Services

If you are a startup, POD is a “safe ticket” to try your hand in the booming activewear/sportswear market.

Benefits:

No need to invest in warehouses, no fear of inventory.
Quick launch with just design ideas.
Flexibility to update new models according to trends.
Significantly reduce financial risks.

Challenges:

POD products are often not tailored.
May be limited in materials or sizes.
Lower profit margins compared to mass production.

For example, Merchize is one of the major POD companies, providing a variety of activewear products such as yoga pants, plus-size leggings, sports bras, etc. They support a wide range of sizes, from 2XS – 6XL for leggings and up to 5XL for sweaters, helping you easily reach customers in many segments.

This form is suitable for POD sellers, startups, and creative individuals who want to test the market before expanding.

Step 4: Create Activewear Designs that Sell

Once you have decided on the product you want to sell, the most exciting step is to create designs. This is where your personality and identity really shine through. Whether you design it yourself or hire a professional designer to help you bring it to life, every detail contributes to making it unique and memorable.

Ask yourself: How can I combine personal style into an activewear line?

If you are pursuing streetwear, think about bold color palettes, bold designs, and quirky logos.
If you are aiming for yoga wear, minimalism, earth tones, and subtle details will create a light, clean feel.
With gym & fitness wear, the energy, strength, and “coolness” should be highlighted with modern sporty details.

Also, you don’t have to be a professional designer to get started. If you’re not comfortable with complex software like Adobe Photoshop or Illustrator, you can always take advantage of user-friendly tools like Canva or Figma. These platforms have a variety of free and paid templates and design elements that allow you to quickly test out ideas.

Pro tip: research the 2025 sportswear design trends (like neutral pastels, gradients, or abstract graphics) to ensure your product is both trendy and personal.

Step 5: Build Your Athleisure Brand Identity

After selecting your product line, it’s time to build your brand. First, consider your fitness brand’s identity and core values. To do this, brainstorm and write down your story. In this content, try to explain where the idea for your athletic apparel line originated, what your brand represents, what makes your products and designs unique, and so on. This helps customers understand why your brand is a perfect fit for their needs.

For example, Lululemon has built its brand on a holistic wellness philosophy, selling more than just yoga or activewear but also promoting an active, mindful, and connected lifestyle. On their website, you can easily see this identity expressed consistently through its imagery, content, and marketing campaigns. This is clear evidence that a successful brand always has a strong and consistent brand identity.

Step 6: Set Up Your Online Store for Activewear

Once you have your products and know what you want to convey, the next step is to introduce them to customers.

The first thing you should do is choose a suitable sales platform. There are 2 options for you: build your own store or join e-commerce platforms like Etsy, Amazon, eBay, and TikTok Shop. If you wanna build your own website, you can work with Merchize. We give you the ability to easily connect seamlessly with most e-commerce platforms and manage the entire sales and fulfillment process in the same system. This will help you save time and focus more on developing your brand.

In addition, don’t forget about the technical aspects like setting up shipping, calculating taxes, and legal procedures (business licenses, tax declarations, etc.). Besides, requirements will vary depending on the sales region, so you may consider consulting an expert to avoid risks. Finally, test the entire ordering process from product selection to payment and delivery to ensure a smooth customer experience. A smoothly running store not only increases satisfaction rates but also helps you build a loyal customer base for the long term.

Step 7: Market Your Activewear Brand Effectively

No matter how great your product is, without a marketing strategy, it is difficult to grow a business in sportswear, streetwear, or any other type of fitness apparel. So remember what you want to stand for and focus on communicating these brand values to your customers.

Invest in visuals

There are no better words to describe a design than a beautiful photo or professional video. Consumers are drawn to activities that have a certain style, so your visuals need to reflect that.

Don’t limit yourself to static or posed shots:
Show movement: Go to the nearest running track, gym, or beach and take photos or videos to showcase your product in action.
Highlight versatility: Take some sports product photos in a professional setting, in the comfort of your home, or on your commute.
Be authentic: A professional model may be the best choice for fashion apparel, but real people who represent your actual customer base will help make your product line more authentic.

Leverage Social Media

When customers are satisfied with a product, they often share their experience by posting photos or videos of themselves wearing the product. This is an extremely valuable form of UGC (User Generated Content), because it is both more authentic and trustworthy than any advertising campaign you create yourself.

For example: A customer buys a stylish gym tank top from your store and posts a workout video on TikTok, tagging your brand. This post can reach hundreds, even thousands of people interested in fitness – the most potential audience for your product.

To make the most of it:

Encourage customers to hashtag or tag your brand with a voucher or discount code.
Offer a small incentive (discount on their next purchase) if they share a photo/video of the product.
Repost customer’s content to your fanpage, Instagram, or TikTok Shop to increase trust and attract new customers.

Creating Hype

One of the most effective ways to grab customers’ attention is to launch limited editions or offer a specific time frame for purchasing. To ensure these strategies work, make sure your product is unique and has its own appeal.

Best Print-on-Demand Activewear Products to Sell in 2025

The print-on-demand sportswear market is hotter than ever, opening up countless options for you to add to your online store. But among the wide range of models, which are the most potential items of 2025, both attracting customers and bringing a ton of orders? Below, we will reveal the sports products that any category should have.

Tank Top

Tank tops are one of the classic sportswear items that are indispensable in any wardrobe. With a minimalist style and a design that focuses on breathability, tank tops provide excellent ventilation, especially when made from sweat-wicking fabric, helping the wearer stay cool and dry during intense workouts.

In particular, Merchize also offers many kinds of tank tops, helping your product stand out in the market, easily attracting the attention of customers who love a different style.

Sport Bras

Leggings and sports bras have long been a classic duo in women’s sportswear. This shirt is an indispensable item for gym enthusiasts, yoga enthusiasts, or high-intensity physical activities. To bring maximum comfort, Merchize products are made from 4-way stretch fabric, hugging the body while still being soft and comfortable on the skin. Sports bras are equipped with removable padding, both supporting the chest area and being flexible for each movement need. In particular, the flat seam and diagonal hem design help minimize friction, bringing a feeling of comfort even during heavy workouts.

Not only focusing on functionality, Merchize also supports on-demand printing (POD), from simple printing to full printing (AOP), allowing sellers to create exclusive products, suitable for many different fashion styles. In addition, we provide full sizes from XS to 5XL, ensuring a suitable fit for many body types, expanding your potential customer base.

Leggings & Yoga Pants

Leggings are very familiar to fashionistas around the world. Whether you’re jogging around the neighborhood, going to the gym or a yoga class, or simply relaxing at home, leggings are always comfortable and versatile.

In the market, there are a lot of kinds of leggings, and it’s hard to stand out with a normal one. This is where Print-on-demand (POD) makes a difference: you can design exclusive leggings from vibrant patterns, outstanding styles, to personalized designs, tailored to each customer group’s needs.

Print-on-demand leggings are not just sportswear; they are also a streetwear and lifestyle trend. This is a potential POD product that you can exploit to expand your customer base and increase revenue.

Jersey shirts and shorts

Jerseys are famous for their loose, airy shape, bringing maximum comfort to the wearer. Therefore, this shirt has long been the top choice for competition and training uniforms of many sports teams. Besides, not only athletes but also sports fans love jerseys as a way to show their pride, often buying them to support or as gifts associated with their favorite team or club. Jersey is not just a uniform, but also a versatile POD product for you to expand your market from the sports community to young people who love street fashion.

Is Activewear Business Profitable?

The answer to this question is yes, with a huge potential for sellers.

Indeed, the global sportswear market size was valued at USD 313.22 billion in 2023 and is projected to reach from USD 314.35 billion in 2024 to USD 558.14 billion by 2032, growing at a CAGR of 6.63% during the forecast period (2024-2032) (following Straits Research). These numbers prove that customers’ demand is growing every day. The reason is that consumers not only buy sportswear for the gym but also use it in their daily lives, such as going to work, going out, or staying at home. The athleisure trend has broken the boundary between workout clothes and everyday clothes.

In addition, many factors are driving the growth of this industry:

Healthy lifestyle and urban fashion: More and more people are concerned about their health and love comfort in dressing. It causes some popular brands, such as Nike or Supreme, to provide clothing that can be worn both at home and while working out.
Influence from social media: Celebrities, influencers, and lifestyle bloggers contribute to spreading the appeal of sportswear, turning it into a global trend.
Changing work habits: Working from home after the pandemic has made many people prioritize comfortable clothes – and sportswear is the number one choice.
Sustainability: The demand for fashion made from recycled, organic, or environmentally friendly materials is increasing rapidly, creating new opportunities for brands focusing on the “green" factor.

However, traditional retailers often face risks because they require a large investment in producing and managing inventory. At this time, the outstanding advantages of print-on-demand service come into play. With this model, you don’t need to worry about inventory and can flexibly add or subtract designs according to trends, as well as combine dropshipping to reduce financial risks.

In short, the activewear business is completely profitable if you know how to leverage e-commerce and POD service. With the market growing rapidly, this is the golden time to participate.

Launch Your Activewear Brand

Reading till here, you might already have a clear picture of how to start selling activewear online. If you are ready to open your own online store or kickstart an activewear business, make sure to do your research carefully. Understand your customer segment, their demand, and collaborate with a supplier that truly supports your long-term goals.

Most importantly, be as active as your customers are. When you share the same passion for sports, fashion, and culture as your audience, your brand becomes more authentic and worth looking forward to.

FAQs

1. How do I start my own activewear brand?

If you want to start selling activewear online, follow these steps:

Step 1: Research and Choose Your Niche

Step 2: Select Products

Step 3: Find a Supplier

Step 4: Create Your Designs

Step 5: Build Brand

Step 6: Set up Online Store

Step 7: Market Your Brand

2. Is selling activewear online profitable?

Yes, selling activewear online is profitable thanks to the industry’s steady growth, high demand, and diverse customer base.

3. How much does it cost to start an activewear business?

Starting an online activewear business can cost anywhere from $0 to $5,000+:

Low-budget option (POD): You can start almost free — just pay for samples, designs, and store setup (Shopify/Etsy subscription + domain, around $50–$100/month).
Wholesale/private label: Requires higher upfront investment ($1,000–$5,000+) for inventory, packaging, and branding.

4. Which platform is best to sell activewear online?

It depends on your business model:

Shopify: Best for building your own branded store with full control.
Etsy: Good for testing designs and targeting shoppers who like unique, custom items.
Amazon: Great for high-volume sales but more competition.
WooCommerce: Flexible if you already have a WordPress website.

For beginners, Shopify + POD suppliers is often the easiest way to start selling activewear online.

How to Sell Activewear Online?