Sustainable Materials in Sportswear: A Guide for Activewear Brands
What Does Sustainability Mean in Sportswear?
Sustainability has become one of the biggest conversations in fashion, but in activewear, it comes with unique challenges. But what exactly does it mean and why is it so important to pay attention to?
Considering that the majority of products in the performance and activewear market use synthetic materials like polyester and nylon, it’s important to look at what options brands have to make more sustainable choices.
We use synthetics in activewear for good reasons: performance, breathability, moisture-wicking, and overall comfort. As discussed in our previous article, nylon can even be a game-changer when it comes to fit and product performance. But the ugly truth is that these materials rely heavily on petroleum and fossil fuels for production.
Before defaulting to virgin synthetics, know that there are better alternatives, including recycled and bio-based options.
What Materials Should Activewear Brands Consider?
With so many options available, it can be overwhelming to know what to choose. While we do not promote the use of recycled polyester, there are plenty of other sustainable alternatives you can explore for your next range.
Here is an overview of both common and alternative materials and what they mean for performance and sustainability in your next activewear range.
Recycled, Regenerated, and Ocean Nylon:
While recycled polyester makes up ~22% of total polyester used in the garment industry, recycled nylon accounts for just 1.9%.
Ocean nylon, a newer generation, is made from reclaimed waste such as fishing nets and marine debris. Both ocean and recycled nylon are broken back down to their base form through chemical recycling, then respun into new fibers.
From a performance standpoint, recycled nylon can replace virgin nylon, but it comes with a higher cost. The process is relatively new, recycling streams are limited, and chemical recycling itself is expensive, all of which keep prices elevated.
Bio-Based Nylon and Polyesters:
Bio-based synthetics are alternatives to traditional synthetics, made from feedstocks such as corn, sugarcane, castor beans, and wheat instead of fossil fuels.
However, “bio-based” does not automatically mean biodegradable. To meet the durability and quality standards of virgin synthetics, these materials are engineered to resist breakdown, so they won’t biodegrade in a landfill.
Bio-based options are promising, but they’re still produced at a smaller scale and remain more expensive than recycled synthetics. Always test them for durability and performance before committing.
Sorona®:
In the Bio-based category, one notable mention is Sorona, a partially bio-based material coming from DuPont. According to DuPont, “Sorona® is 337% plant-based (corn glucose). Its production uses 44% less energy and generates up to 63% fewer greenhouse gas emissions compared to conventional nylon 6.”
From a performance standpoint, Sorona® offers comfort, durability, stretch, and recovery. This makes it a strong alternative to conventional synthetics for activewear, athleisure, and outdoor apparel.
Responsibly Sourced Merino Wool:
For sustainability and performance in the outdoor market, wool is a strong contender. It’s natural, renewable, and biodegradable. Responsibly sourced wool comes from regenerative and organic farms and is often traceable back to the source.
Wool offers natural moisture management, thermal regulation, and is naturally anti-odor, making it ideal for base layers and running gear. Where it falls short is strength, stretch, and recovery, without elastane it won’t perform for tights or heavy training wear. Wool is also relatively expensive, which can also be a barrier.
Lyocell (Tencel):
Lyocell, originally developed as a sustainable alternative to viscose rayon, is made from sustainably sourced wood pulp and cellulose. A non-toxic solvent is used in a closed-loop process, meaning it can be filtered and reused, making it much more environmentally friendly than conventional viscose.
The result is a fabric that’s soft, lightweight, breathable, and moisture-managing. It’s also naturally antimicrobial, making it perfect for yoga apparel or warm-weather tops. Downsides: it can shrink and wrinkle.
EcoVero™:
EcoVero is Lenzing’s answer to conventional viscose. Made from wood pulp sourced from certified sustainable forests (FSC or PEFC) and is made in a system that reuses most of the water and chemicals. The result: less pollution, lower impact.
EcoVero fabrics are soft, breathable, and moisture-wicking, making them comfortable for athleisure or warm-weather styles. Unlike synthetics, they’re fully biodegradable and compostable, though higher costs remain a consideration.
Modal:
Modal, also from Lenzing, is produced from beech trees, usually in a closed-loop process that captures and reuses nearly all of the chemicals involved. This process greatly reduces pollution and water consumption.
The fabric itself is smooth, stretchy, and naturally breathable, making it popular for use in activewear and loungewear. Because Modal can be biodegradable and compostable when certified, it can be a lower-impact choice. Just check that it’s FSC-certified to confirm the wood pulp was responsibly sourced.
Hemp:
Considered the “gold standard” in sustainable materials, hemp is a fast growing natural resource for textiles use. Compared to conventionally grown cotton, hemp uses less water, requires fewer pesticides, can improve soil health, and yields high fiber output per acre.
Super strong, durable and resistant to wear, hemp is naturally biodegradable and naturally antimicrobial, contributing to less odor build-up in garments. Hemp is also naturally breathable, absorbs moisture, and naturally regulates temperature, which makes it great for use in activewear.
Hemp production and processing can involve relatively large quantities of fertilizer and machinery, both of which use a lot of water, so ensure that you are sourcing hemp from certified organic farms. Its natural strength means that it can feel stiff, so blending with cotton and other natural fibers is needed to give it a softer handfeel.
Organic Cotton:
The most popular natural fiber choice for casual wear and athleisure applications is Cotton. While cotton is a natural resource that is biodegradable, cotton does require a lot of water to grow, and sustainability needs to be taken into consideration when choosing this natural resource.
Conventionally grown cotton requires a lot of pesticides and fertilizers for growth, which is why it is important to look for organic cotton or cotton grown using regenerative agriculture. (Regenerative agriculture actively ensures soil health is restored through the growing and cultivation process).
Because it is a natural fiber, cotton is soft, durable and super versatile; it can be used across a variety of athleisure and lifestyle products. It does hold onto moisture and without elastane can feel restrictive, so is not the first choice for active styles.
Bamboo:
Bamboo is fast-growing and requires little water, which is why it’s often seen as a sustainable alternative. Thanks to its fiber structure, bamboo offers a soft handfeel, breathability, durability, odor resistance, and UV protection, making it appealing for outdoor apparel and for people with sensitive skin.
The catch is in the processing. Most bamboo fabrics are made through an energy-intensive and chemical-intensive method to turn the plant into usable fibers, which undermines its eco-friendly reputation.
If you want to use bamboo, look for versions produced with a mechanical closed-loop process and verified by OEKO-TEX or FSC certifications. While OEKO-TEX is fairly common, truly sustainable bamboo options (like closed-loop or FSC-certified) are much less widespread in the market.
Why Recycled Materials Are Better for Sportswear
In some applications, 100% natural fibers won’t achieve the close-to-body fit and durability performancewear requires. That’s why choosing the right sustainable alternative matters. When synthetics are necessary, opt for recycled or natural alternatives over virgin.
Why?
- Lower impact: Recycled materials use less energy overall compared to virgin, resulting in lower emissions.
- Waste reduction: They repurpose existing plastic and nylon waste, keeping it out of landfills and oceans while reducing reliance on fossil fuels.
- Consumer expectation: More and more consumers not only want sustainable materials but expect brands to be using them.
(Learn more via Textile Exchange)
How to Choose the Right Sustainable Material for Your Activewear Range?
The best choice depends on your product, its intended activity, and your price point. Material selection is one of the most critical steps in building sustainable product ranges.
But the first step is partnering with a manufacturer that values sustainability as much as you do.
At Activewear Productions, we support brands from concept to creation, helping teams make smarter material choices and navigate the full development process. You can learn more about our approach to sustainability here.
To explore our full range of services, visit our homepage. And if you’re an experienced brand looking for a reliable partner on your sustainable activewear journey, connect with us here, we’d love to hear from you.