How to Create an Activewear Tech Pack with AI
Create activewear tech packs with AI — performance fabric specs, flatlock seam construction, moisture management details, and athletic fit grading.
Activewear tech pack requirements
Activewear tech packs have unique requirements compared to casual wear. Performance fabrics need stretch and recovery specifications, seams must be flat to prevent chafing, and construction must withstand repeated washing and high-intensity movement.
The BOM for activewear includes technical specifications that casual garments do not need: moisture management properties, UPF rating, four-way stretch percentage, and recovery rate.
Performance fabric specifications
Activewear fabrics need detailed technical specs beyond composition and weight.
- Stretch: percentage of stretch in warp and weft (4-way stretch typical: 30-40%)
- Recovery: percentage of recovery after stretch (target: 95%+)
- Moisture management: wicking treatment, dry time, breathability rating
- Weight: typically 160-240 gsm for performance fabrics
- Composition: polyester/spandex, nylon/spandex, or blends
- Finish: anti-microbial, anti-odor, UV protection rating
Flatlock and bonded seam construction
Activewear uses flatlock seams (stitch type 607) instead of standard overlocked seams. Flatlock seams lay flat against the skin, preventing chafing during movement. Some premium activewear uses bonded seams — heat-sealed joins with no stitching.
AI tech pack generation for activewear automatically specifies flatlock construction, appropriate stitch types, and chafe-free seam placement. Critical seam positions (inner thigh, underarm) get specific callouts for flat construction.
Athletic fit and grading
Activewear grading differs from casual wear. Athletic fit requires maintaining the stretch-to-body ratio across sizes — simply scaling up casual measurements produces activewear that fits differently at larger sizes.
Key activewear POMs include: stretched chest measurement, relaxed and stretched waist, inseam (for leggings/tights), and armhole depth. The AI applies activewear-specific grade rules that account for fabric stretch.
Activewear-specific tech pack details
Beyond standard sections, activewear tech packs need: gusset specifications (for leggings), waistband construction (wide elastic, drawcord tunnel, or bonded), key pocket specifications (size, zipper type, waterproof lining), and reflective detail placement.
The AI generates these specialized sections based on your activewear type — leggings get gusset and waistband specs, sports bras get support construction details, and running jackets get reflective placement callouts.