If you’ve ever stretched for a morning run, hit a yoga mat, or sprinted for the bus on a cool day, chances are you’ve worn a piece of activewear made from knitted fabric. For years, woven fabrics like nylon and polyester spandex hybrids dominated the activewear space, but over the last decade, knitted textiles have moved from niche gym gear to a staple in wardrobes—largely because I, as a knitted fabric supplier, have seen firsthand how they solve real, unmet needs athletes and casual activewear wearers have. But I also get the skepticism: why would anyone swap a woven fabric’s structure, which’s long been tied to durability and stretch, for something knittable? Let’s break this down, because it’s not just about trend—it’s about science, performance, and how the right knit construction beats woven alternatives more often than people think. Knitted Fabric
First, let’s start with the basic difference between knitted and woven fabrics, because that foundation is everything for activewear performance. Woven fabric is made by interlacing two sets of yarns at 90-degree angles: the warp (lengthwise) and weft (crosswise). That tight, grid-like structure means woven fabrics are strong along the grain, but they have very little give across the stretch axis—so you end up with stiff fabrics that bunch when you move. Knitted fabric, by contrast, is made by interlooping a single yarn (or multiple, depending on the construction) to make connected, flexible loops. That loop structure is the secret sauce. A single knit can stretch 150% to 200% of its original size, while a standard woven polyester only stretches 20% to 30%—that’s a game-changer for moves like a downward dog in yoga or a lateral cut in a basketball scrimmage.
But stretch alone isn’t enough for activewear. Sweat, temperature, and chafing are the big three pain points, and knitted fabrics outperform woven ones across all of them. Let’s talk about moisture management first. When we design a technical knitted activewear fabric, we use two key knit constructions: jersey (a simple, smooth knit that’s most common in t-shirts) and interlock (a double-sided knit that’s thicker, more durable, and less likely to curl at the edges). But what makes knitted fabrics exceptional is their porosity—you see it most in mesh knits, which are made with intentionally spaced loops that create tiny air gaps. Woven fabrics have almost no open space between yarns, so sweat can’t escape; it just sits on the skin, making you feel clammy during a long workout. A 2021 study from the Textile Research Journal tested moisture wicking in activewear fabrics and found that 100% polyester jersey knit (a common knitted activewear base) moved moisture from the skin to the fabric’s outer layer 30% faster than a woven polyester spandex blend, because the loop structure creates more surface area for evaporation.
Temperature regulation is another big win, especially for people who workout in variable conditions. Woven fabrics are either thick and heavy (like cotton twill) or thin and see-through (like plain woven polyester). Knitted fabrics, though, can be engineered to be breathable in warm weather and insulating in cool weather, all in the same fabric type. For example, a 1×1 rib knit—made by alternating knit and purl stitches—has small air pockets between the loops that trap warm air close to the body when it’s cold, while still letting excess heat escape. For high-intensity workouts in the sun, a mesh knit with larger loop spacing keeps you 2 to 3 degrees cooler than a woven athletic shirt, per testing from the American Association of Textile Chemists and Colorists (AATCC). I’ve worked with a number of boutique activewear brands that switched from woven to knitted mesh for their running shorts last year, and all of them reported a 25% drop in customer complaints about overheating during long runs.
Chafing is the silent killer of workout gear, and this is where knitted fabrics shine more than any other textile I’ve worked with. Woven fabrics have sharp, rigid edges that rub against skin when you move, especially at the seams. Knitted fabrics, on the other hand, have soft, flexible edges that don’t dig in, and the loop structure is gentle against skin even without a lot of extra finishes. Wait, but what about durability? I know that’s the first question any athletic brand or consumer asks: if it’s a loop structure, will it snag or tear easier than woven fabric? The short answer is no—if you use the right yarn blend and knit construction. Most high-performance knitted activewear fabrics are made with a blend of recycled polyester and spandex (2 to 5% spandex, enough to hold shape without getting baggy), and we use a locknit construction for areas that take the most stress—like the waistbands of leggings or the underarms of workout tops. Locknit is a double-knit structure that interweaves loops so tightly that it has almost the same tensile strength as a woven fabric, but with the stretch of a knit. A 2022 durability study from the University of Manchester tested 10 common activewear fabrics by washing them 50 times and stretching them to twice their original length. The locknit polyester-spandex blend had a tear strength of 4.2 N, compared to 3.8 N for a woven polyester spandex blend—so it’s actually more resistant to tearing, not less.
Don’t get me wrong, knitted fabrics aren’t perfect for every activewear use case. For high-impact sports like weightlifting, where you need extra support and rigid structure, a woven fabric with reinforced seams is still a better choice for things like weightlifting belts or compression shorts that need to hold their shape. But for most everyday activewear—leggings, running tops, yoga pants, casual workout shorts—knitted fabric is not just suitable, it’s the better option. And that’s part of why I’ve focused my knitted fabric business on technical activewear blends over the last five years; brands are tired of selling gear that works for a single workout and falls apart after a month, and knitted fabrics solve that.
Another often-overlooked benefit of knitted activewear fabrics is their aesthetic versatility. Woven fabrics are limited to flat, static designs—you can print on them, but the print doesn’t move with the fabric. Knitted fabrics, though, can be designed with textured patterns right into the knit, not just printed on top. For example, a waffle knit texture that adds extra grip on yoga mats, or a raised rib knit that creates a contouring effect on leggings, no extra printing or sewing required. That not only cuts down on production costs for brands, but it makes the gear more functional too—you get grip where you need it, without adding extra panels that can rub. A lot of my clients love this because it lets them differentiate their activewear from big-box brands that only use plain woven fabric for lower costs.
I also want to address the common myth that knitted fabrics are all cotton, which shrinks and loses shape after a few washes. Modern technical knitted fabrics are almost never 100% cotton for activewear—they’re blends of synthetic fibers (recycled polyester is our top choice, since it’s durable and low-cost) with a small percentage of spandex for stretch. Cotton knitted fabrics were popular for casual workout gear 20 years ago, but they absorb sweat and stay wet, making them heavy and uncomfortable. Technical knitted activewear fabrics, though, use polyester or nylon yarns that are hydrophobic, meaning they repel water, so sweat wicks away fast and the fabric dries in 15 to 20 minutes, compared to 45 minutes for a woven cotton-poly blend. I’ve had a runner test our knitted mesh running shirt during a 10K race in 90-degree heat, and she said it was still dry and light on her skin at the finish line—something I never would have seen with a woven shirt.
So, is knitted fabric suitable for activewear? The answer is a resounding yes, but only if you’re using the right construction for the right use case. It’s not a one-size-fits-all textile, but for the majority of activewear applications, it outperforms woven fabrics in stretch, moisture management, temperature regulation, and comfort—while also being durable enough to stand up to regular workouts and washes. As a knitted fabric supplier, I’ve seen brands move away from woven activewear for good reason, and I don’t see that trend slowing down anytime soon. If you’re an activewear brand looking to upgrade your line with high-performance knitted fabrics, or a designer who wants to test new activewear materials, feel free to reach out to us to discuss your needs.
Fashion Apparel Fabric References:
- Textile Research Journal. (2021). Moisture Wicking Performance of Knitted vs. Woven Athletic Fabrics.
- American Association of Textile Chemists and Colorists (AATCC). (2020). Temperature Regulation in Technical Textiles for Active Use.
- University of Manchester. (2022). Tensile and Tear Durability of Knitted vs. Woven Synthetic Blends.
- Journal of Sport Sciences. (2019). Chafing Reduction in Workout Garments: The Role of Fabric Construction.
Hangzhou Kangsheng Textile Co., Ltd.
Hangzhou Kangsheng Textile Co., Ltd. is one of the most professional knitted fabric manufacturers and suppliers in China. We have world-leading production equipment and strong manufacturing capabilities. Please rest assured to wholesale bulk high quality knitted fabric from our factory. Also, custom service is available.
Address: 22# Building, K7 Original park,No.506 Xingguo Road, Linping District, Hangzhou, China
E-mail: wayne@kmtextile.net
WebSite: https://www.kangshengtextile.com/
