Custom base layers for sport and outdoor brands
Performance base layers that move moisture away from the skin: grid fleece for ski and hiking, lightweight wicking knits for running and cycling, and merino blends for multi-day use. Plain or custom printed, from 100 pieces per style.
- 100 pieces per style, your label, your colours
- Grid fleece, waffle, seamless and merino blends
- Flatlock seams, raglan sleeves, thumbholes as standard options
- Custom printed by sublimation or heat transfer
Base layers we make
| Style | Fabric options | Weight | Sizes |
|---|---|---|---|
| Ski and hiking base layer top | Polyester grid fleece, brushed back | 180–240 gsm | XS–3XL |
| Base layer bottoms | Polyester grid fleece or brushed poly-spandex | 180–260 gsm | XS–3XL |
| Running / training base layer | Lightweight wicking polyester-spandex | 130–180 gsm | XS–3XL |
| Cycling base layer | Mesh or light wicking knit, sleeveless or short-sleeve | 100–160 gsm | XS–3XL |
| Seamless base layer | Nylon-spandex, body-mapped knit zones | 150–220 gsm | S–XL |
| Merino blend base layer | Merino-polyester or merino-nylon | 150–250 gsm | XS–3XL |
Minimum 100 pieces per style with your label, sizes mixed. Custom fabric, colour or fit from 500 pieces per colour. How MOQ and pricing work →
What you can change
- Fabric, weight and fit (compression, athletic, regular)
- Raglan or set-in sleeves; thumbholes; half-zip neck
- Flatlock seams throughout, and placement away from pack straps
- Custom printed: all-over sublimation on polyester, or heat-transfer logos
- Reflective details for running
- Colour: stock colours, or dyed to your Pantone from 500 pieces per colour
How a base layer is made
Knitting
Yarn is knitted on circular knitting machines into tubular fabric at the weight you choose, measured in grams per square metre (gsm).
Brushing and setting
For brushed fabrics the inner face is napped to raise a soft pile that traps warm air. The fabric is then heat-set so width and shrinkage stay stable after washing.
Cutting
Fabric is laid and cut to a marker built from your size ratio, so a mixed-size order does not waste fabric.
Sewing
Flatlock seams for base layers that sit against the skin, overlock and cover-stitch for everyday thermals, rib cuffs and waistbands attached on the same line.
Check and pack
Every piece is measured against the size chart, trimmed and inspected, then folded and bagged with your label, size sticker and barcode.
Warmth is not the only job
A base layer has to move sweat off the skin first; warmth comes from staying dry. That is why sport base layers use polyester and merino rather than cotton, and why the right weight depends on the activity: light for running and cycling, heavier grid fleece for standing still on a ski lift.
Custom printed base layers
Sublimation printing dyes the pattern into polyester, so it does not crack or peel and does not change how the fabric breathes. It suits team kits, club base layers and bold all-over designs. Logos on merino and cotton blends are applied by heat transfer instead.
Also made here: Thermal tops · Fabric guide · Private label
Frequently asked questions
What is the minimum for custom base layers?
100 pieces per style with your label. Custom printed and custom-dyed fabrics start at 500 pieces per design or colour.
Can you make a custom cycling base layer?
Yes, sleeveless and short-sleeve in light mesh or wicking knits, plain or printed.
Do you make 100% merino?
We make merino blends as standard. 100% merino is possible on request; it costs more and needs a longer lead time for the yarn.
How long does it take?
Samples in about 7 days, bulk in about 25 days after approval and deposit. Printed designs add a few days for strike-offs.