Stretch garment engineering

Custom Leggings Manufacturing

A leggings brief ties together fabric extension, recovery, coverage, seam comfort and grading. Fenalt coordinates the specification and sample review through a managed production route.

SilhouetteFabricConstructionFit approval

Cut and shape

Four silhouettes, different build choices

PROFILE 01

High-waisted tight

Double-layer waistband, internal elastic or bonded edge, and a gusset shape specified for the pattern.

PROFILE 02

Seamless sculpting style

Circular-knit body with zones and texture described in the approved product brief.

PROFILE 03

Pocket or cargo tight

Side-drop or concealed pocket positions balanced against stretch and garment fit.

PROFILE 04

Flared or stirrup legging

Calf-to-hem shape and foot anchor captured in the grading and fit review.

Fabric selection

Choose by hand-feel and intended use

These are composition and weight examples, not performance guarantees. Set coverage, stretch and recovery criteria in the brief, then evaluate the actual sample.

Material direction	Illustrative specification	Product brief
Nylon / elastane interlock	75% nylon / 25% elastane · 220–260 GSM	Yoga, studio and Pilates briefs
Polyester performance blend	80% recycled polyester / 20% elastane · 260–310 GSM	Training and running options
Brushed microfiber	85% nylon / 15% spandex · 280–320 GSM	Cold-weather product direction
Cotton-touch blend	88% combed cotton / 12% elastane · 230–270 GSM	Athleisure and lounge

Seam and support

Engineer for movement, then validate

Construction decisions include flatlock seam (ISO 607), gusset geometry, waistband layers and stretch thread as decision areas. It cites 12–14 SPI as a starting specification; confirm the stitch plan on the chosen fabric.

Flatlock seams

Specify seam position, thread and stretch behavior; assess the join at the agreed extension.

Gusset

Choose triangular or elongated diamond geometry to distribute crotch intersections.

Waistband

Select self-fabric folds, power-mesh lining, elastic or a bonded edge according to the brief.

Print and branding

Check that transfers, silicone print or embroidery move with the selected stretch fabric.

Sample review

Make fit approval a clear gate

01
Pattern
Review flat sketches, POM table and stretch assumptions before sample development.
02
Proto
A 10–15 day sample window is a planning reference; confirm scope and delivery for each project.
03
Fit review
Assess waistband behavior, gusset comfort, seam placement and stretch recovery against agreed criteria.
04
PPS
Record fabric, trims, grade and design approval before considering bulk production.

Activewear project

Share the fit, fabric and movement brief

Include silhouette, fiber direction, weight, POMs, grade, seam details, branding and sample criteria.

Discuss a leggings brief