Technical Activewear • Client: IronClad Athletic Apparel Co. (USA) (2025)
IronClad Performance Activewear & Compression Line
Private-label compression wear and performance training apparel line for a fast-scaling North American boutique fitness brand, featuring 6-needle flatlock anti-chafing construction and custom silicone waist grips.
01 / Production Gallery & Construction Details
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02 / Manufacturing Challenge & Engineering Execution
The Client Challenge:
Producing squat-proof, non-sheer compression leggings and rashguards capable of withstanding barbell knurling friction while maintaining comfortable four-way dynamic elasticity.
The HR Sports Solution:
Selected the 240 GSM PowerFlex Polyamide-Elastane blend with interlock density weaving. Applied specialized anti-slip silicone interior waist ribbing and flatlock seam reinforcements that eliminate skin irritation during high-intensity training.
03 / Verified Client Feedback
“Our return rates dropped to under 0.8% after switching our activewear production to HR Sports. The compression fit and hand-feel are phenomenal.”
Samantha CruzChief Product Officer — IronClad Apparel Co.
Factory Audit Sheet
Batch Specifications
Batch Volume:8,500 Units (Leggings, Tops, Shorts)
Production Time:18 Business Days
Fabric Composition:78% Polyamide 6.6, 22% Elastane
Seam Construction:6-Needle Heavy Duty Flatlock
Branding Details:High-Density Reflective Heat Seals
Packaging:FSC-Certified Matte Polybagging
Fabrics Milled:
PowerFlex™ Compression Matrix (240 GSM)OceanThread™ Eco-Performance (165 GSM)
Volume Batch:8,500 Units
NDA & Client IP Protected
Pattern geometry and color profiles for this project are securely archived under mutual non-disclosure.