Sports Bra Tech Pack: What to Include for Manufacturing
A sports bra has more parts than almost any other activewear piece: layers, pads, elastics, straps and sometimes closures. Each one affects fit and support, so the tech pack needs more detail than a leggings tech pack. This checklist covers what to include, from the factory side.
- Cover page with the support level, activity, size range and route.
- Flat sketches with an inside view of the lining, pad pocket and elastics.
- Bill of materials covering shell, lining, elastics, pads and closures.
- Points of measure with tolerances, measured relaxed and extended where needed.
- Construction, pads, colorways, logos, labels and a wear-test requirement.
This guide builds on our general activewear tech pack checklist and focuses on what is specific to sports bras.
1. Cover page: start with support
- Support level and activity: low, medium or high support, and what the bra is for, such as yoga, gym or running. See our guide to sports bra support levels.
- Construction route: Cut & Sew or seamless.
- Size range: for example XS–XL, or up to 3XL for Cut & Sew.
- Style name, season, target quantity per color and key dates.
2. Flat sketches, including the inside
Draw the front, back and side flat, and add an inside view. Sports bras are built in layers, and the inside view shows the lining, the pad pocket opening and where elastics sit. Add callouts for:
- Neckline shape and height
- Strap style and how straps attach: fixed, adjustable, halter, cross-back or racerback
- Back style: open, closed or keyhole, and any back closure
- Underband: height, elastic and whether it is enclosed
- Pad pocket opening and its position
- Edge finishing, seam lines, panels and any mesh zones
- Logo positions
3. Bill of materials
| Item | What to specify |
|---|---|
| Shell fabric | Composition, weight in gsm, hand feel, finish and stretch, for example 78% nylon / 22% spandex, 220 gsm, brushed |
| Lining | Fabric, number of layers and which panels are lined |
| Underband elastic | Width, type, and whether it is enclosed or exposed |
| Strap and edge elastic | Width and where each is used |
| Pads | Removable or not, shape, thickness and size per garment size |
| Closures and adjusters | Type, size, color and finish of any back closure or strap adjusters |
| Thread | Color, matched or contrast |
Not sure which fabric fits? Our sports bra fabrics range from soft 78/22 nylon blends to 70/30 for extra stretch and 80/20 polyester for prints; compare them in our nylon vs polyester guide.
4. Points of measure, tolerances and grading
Measure the bra flat. Because elastics and stretch fabric change size under tension, measure the underband and other elastic edges both relaxed and extended (stretched to their limit).
| Point of measure | Notes |
|---|---|
| Underband, relaxed and extended | The most important point for support and fit |
| Underband height | Wider bands give more support |
| Chest width | Measured across, armhole to armhole |
| Center front height | From underband to neckline |
| Back height and side seam height | Sets coverage at the back and sides |
| Strap length and width | Note the adjustment range for adjustable straps |
| Armhole | Measured along the curve |
| Neck width, front and back neck drop | Defines the neckline shape |
| Pad size | Width and height for each garment size |
Give every point a tolerance and a grading chart across all sizes. Plus sizes usually need wider bands and straps for the same support, so grade those widths too, not only the lengths. See how to check support across sizes.
5. Construction
- Layers: single or double layer, and which panels are doubled.
- Seams: flatlock, coverstitch or overlock, and where each is used. Our Cut & Sew bras are sewn with flatlock seams and clean edge finishing.
- Edges: how the neckline, armholes and underband are finished.
- Stretch direction: the direction of greatest stretch, usually around the body.
6. Pads and pad pockets
Specify whether pads are removable, their shape and thickness, and where the pocket opens. Our sports bras are made with pad pockets and removable pads, and pad shape and thickness are confirmed on the sample. Note the pad color too, as it can show through light fabrics.
7. Seamless sports bras
Seamless bras are knitted to a program on Santoni machines rather than cut and sewn. Instead of seam lines, describe the knit zones (rib, mesh and support zones), any ruching or contour effect, and the hand feel. Our seamless bras use a 90% nylon / 10% spandex yarn, are made in XS–XL and start from 500 pieces per style per color.
8. Colors, logos, labels and packing
List each colorway with Pantone TCX references, including the lining, elastics, thread, pads and logo. For logos, give the method (silicone, heat transfer or embroidery), size and position measured from a fixed point, such as 2 cm below the neckline at center front. Add your labels, hangtags and packing; see our private label guide.
9. Support and wear-test requirements
Write down how you will judge support on the sample: the activity to test, and what counts as a pass, such as no excess bounce, an underband that stays in place, straps that do not dig in and pads that do not move. This turns comments like “needs more support” into changes the pattern maker can make.
Common sports bra tech pack mistakes
- Underband measured only relaxed, or with no tolerance.
- No inside view, so the pad pocket and lining are guessed.
- Pad size not graded across sizes.
- Lining, elastic and pad colors left out of the colorway.
- Support described only as “high” without an activity or a reference bra.
No tech pack? Start from a reference bra
You can start with a reference bra and notes on what to change, photos, a sketch, or one of our current sports bra styles. Our pattern makers develop the pattern at no extra cost, and once you approve the sample, its measurements and materials become the specification for bulk. Samples take 12–15 days and cost US$10–15 per style, refunded on bulk orders; see our sampling process guide.
Frequently asked questions
What should a sports bra tech pack include?
A cover page with the support level and size range, flat sketches including an inside view, a bill of materials, points of measure with tolerances and grading, construction details, pad and pocket specifications, colorways, logo placement, and labels and packing.
What are the key measurements for a sports bra?
Underband (relaxed and extended), chest width, center front height, back height, side seam height, strap length and width, armhole, neck width and neck drops, underband height and pad size. Each needs a tolerance and a grading chart across sizes.
How do I specify pads in a sports bra tech pack?
State whether pads are removable, their shape, thickness and size per garment size, and where the pad pocket opens. Pad shape and thickness are confirmed on the sample.
How is a seamless sports bra tech pack different?
Seamless bras are knitted to a program rather than cut and sewn, so describe the knit zones (rib, mesh and support zones), the ruching or contour effect, and the hand feel, instead of seam lines and pattern pieces.
Do I need a tech pack to make sports bras with MIDYOGA?
No. You can start from a reference bra, photos, a sketch or one of our existing styles. Our pattern makers develop the pattern at no extra cost, and the approved sample becomes the specification for bulk.
What size range can you make sports bras in?
Cut & Sew sports bras can be made in XXS–XL with plus sizes up to 3XL. Seamless sports bras are made in XS–XL.
Have a sports bra tech pack ready?
Tell us about your style and quantity, then email your tech pack or reference photos. We review the details 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.