Activewear Quality Control Checklist for Buyers
AQL tells you how many garments to check. This checklist covers what to look for on each one. Use it to agree your requirements with your manufacturer, review samples and inspect bulk activewear, from fabric and seams to logos, pads and packing.
- Inspect against the approved sample, not your memory of it.
- Agree acceptance rules before bulk, including how each defect is classified.
- Stretch garments as you check them, because some faults only show under tension.
- Wash a sample, because shrinkage and twist can appear later.
- Use a test lab when you need a measured result, not just a quick check.
Set acceptance criteria before bulk production
An inspection only works if everyone uses the same rules. Before production starts, agree these points:
- The approved sample and tech pack version
- Key measurements, tolerances and how they are measured
- Approved fabric, trims and color references
- Any function tests, such as stretch or opacity
- How each defect is classified
- Your sampling plan, such as AQL 2.5
The table shows how common findings are often classified. Your own inspection plan decides the final class.
| Finding | Often classified as |
|---|---|
| Anything that could harm the wearer, or a compliance failure | Critical |
| Open seam, skipped stitches that can open under stretch | Major |
| Measurement outside tolerance | Major |
| Clear color difference, including within a set | Major |
| Logo peeling, cracked or in the wrong position | Major |
| Wrong size label or missing pad | Major |
| Short loose thread or small stitching irregularity | Minor |
Our AQL 2.5 guide explains sample sizes and how to count results, and our quality control page shows the checks through production.
Fabric and color
- Fabric condition: look for holes, snags, marks and uneven areas before cutting and on finished garments.
- Fabric match: compare weight, hand feel and finish with the approved sample.
- Shade variation: compare panels within one garment, garments within one color, and pieces within a set. Use agreed lighting, and see how to match colors on repeat orders.
- Opacity: stretch light colors over a hand or test them in a squat. Our squat-proof guide explains how.
Colorfastness to sweat: for a quick check, rub a damp white cloth on the fabric and look for color transfer. This can show a risk, but it is not a test result. Dark and bright colors deserve a lab test, such as ISO 105-E04 or AATCC 15, because sweat and friction are part of normal use for activewear.
Seams and stitching
Inspect seams with the garment stretched as well as relaxed, because many stitching faults only show under tension.
- Skipped stitches: gently stretch the seam and look along it under good light. A gap in the stitch pattern can open with wear.
- Seam strength: stretch high-stress areas such as the crotch, waistband and underband. Listen and look for popping threads.
- Seam stretch: the seam should stretch with the fabric and recover.
- Seam appearance: check for puckering, wavy edges and seams that show gaps when stretched.
Check that the seam type matches your specification. Our seam guide explains the main options.
Measurements, stretch and recovery
Measure key points flat, in the same way as your specification, and compare them with your tolerances. Check several sizes, not only the base size. For waistbands and underbands, measure both relaxed and extended.
For a quick stretch recovery check, measure an area, stretch it several times and measure it again after it has rested. If it stays longer or looks baggy, compare it with the approved sample. For a measured stretch and recovery result, use a test lab.
Wash tests: shrinkage and twist
Some problems only appear after the first wash, so wash at least one garment from production.
- Measure first. Record the key points before washing.
- Wash and dry it. Follow the care label.
- Let it rest. Lay it flat before measuring, especially seamless garments, which relax after knitting and washing.
- Measure again. Compare the change with your agreed tolerance.
- Check the shape. Lay it flat and look for twist, color change and any logo problems.
Spirality is a twist in knit fabric that can pull side seams or knit lines out of place. It matters on seamless garments and fitted leggings, where a twisted seam is easy to see. Compare both sides of the garment, before and after washing.
Product-specific checks
| Product | What to check |
|---|---|
| Leggings | Waistband stretch and finish, pocket placement on both sides, crotch seam, and opacity |
| Sports bras | Both pads present, matching and flat; pad pocket opening; underband; strap symmetry |
| Seamless | Knit zones in the correct position, dropped stitches or holes, stretch and symmetry |
| Shorts and skirts | Inner shorts attachment, pockets, hem finish and pleat shape |
| Jackets | Zipper movement, pockets, collar shape and thumbholes where used |
| Sets | Color match across pieces, and matching sizes and packs |
For bulk leggings with pockets, use the approved sample or a template to compare placement across sizes. For removable pads, check a sample of garments by hand, and wash one to see whether the pads stay flat. Our guide to sports bra support across sizes covers wear testing.
Logos and trims
- Position: measure from the same fixed point as your tech pack, on several sizes.
- Heat transfers: look for lifted edges, bubbles and shiny marks around the logo.
- Stretch: stretch the logo area, then check for cracks and whether it recovers.
- Wash: check for peeling, fading or color change.
- Trims: test zippers, drawcords and elastics, and compare trim colors with the fabric.
See our logo options guide for how methods differ.
Labels and packing
- Size label matches the actual garment
- Neck, care and fiber content labels are correct
- Hangtags and barcodes match the style, color and size
- Folding and polybags follow your instructions
- Carton quantities, marks and assortments match the packing list
Scan a sample of barcodes rather than only reading them. A correct garment with a wrong barcode can still cause problems at a warehouse.
Quick checks and lab tests
| Check | Quick check | When to use a test lab |
|---|---|---|
| Colorfastness | Damp white cloth | Dark or bright colors, and retailer requirements |
| Shrinkage | Measure, wash and measure again | When you need a recorded result or a set limit |
| Stretch and recovery | Stretch, rest and measure again | Compression claims or tight tolerances |
| Pilling | Rub and wear the sample | Comparing fabrics, or high-friction styles |
| Seam strength | Stretch by hand | Repeat failures or high-stress garments |
A quick check is useful, but it does not replace a test report. If your market or a retailer requires testing, confirm the method and the pass level with a test lab, and share the requirements before sampling and bulk production.
If an inspection fails
Do not make the decision from a single photo. Look at the defect class, how many pieces are affected and whether the problem can be repaired. The usual options are to sort the lot, repair affected garments and inspect again. Keep the findings, photos and decision with the order, so the same issue can be avoided next time.
Common mistakes
- Inspecting without the approved sample on the table.
- Agreeing defect classes only after a problem appears.
- Checking seams only when relaxed.
- Measuring one size and assuming the rest are correct.
- Skipping the wash test.
- Treating a quick check as a test report.
- Leaving labels and cartons until the last minute.
Frequently asked questions
What should an activewear quality control checklist include?
It should cover fabric and color, seams, measurements, stretch, logos and trims, labels and packing, plus any product-specific details such as pads or pockets. Everything should be judged against the approved sample and specification.
How do I check activewear colorfastness to sweat?
For a quick check, rub a damp white cloth on the fabric and look for color transfer. For a reliable result, ask a test lab to run a perspiration test, such as ISO 105-E04 or AATCC 15, especially on dark and bright colors.
How do I check wash shrinkage?
Measure key points, wash and dry the garment according to the care label, then measure the same points again. Compare the results with your agreed tolerance.
What is spirality in activewear?
Spirality is a twist in knit fabric that can make side seams or knit lines turn away from their correct position, often after washing. Check it by laying the garment flat before and after a wash.
How are activewear defects classified?
They are usually classed as critical, major or minor. Critical findings are safety or compliance issues, major findings affect use, fit, appearance or saleability, and minor findings are smaller workmanship issues. Agree the classes before bulk production.
Can I use third-party inspection or testing?
Yes. Share your tolerances, testing requirements and third-party inspection needs before sampling and bulk production, so they can be planned into the order.
Have quality requirements to share?
Tell us your tolerances, tests or inspection plan, and the styles you have in mind. We review them and reply with a quote within 24 hours. Only your work email is required.
- A tech packShare technical drawings, measurements and material requirements.
- A reference productShare a photo, product link or sample, with the details you want to develop.
- An early ideaDescribe the category, intended activity and wearing experience.