How Many Samples Does a New Activewear Brand Really Need?
Learn which activewear sample stages a new brand may need, from prototype and fit sample to size set and pre-production sample-without unnecessary rounds.
Sampling is one of the most important and potentially costly stages of activewear development. Understanding which sample stages are necessary helps new brands budget effectively.
Key Sample Stages
1. Prototype Sample
The first physical version of the design. Used to evaluate construction, fabric suitability and overall concept viability.
2. Fit Sample
Refined version focused on measurements, fit and comfort. Multiple fit rounds may be needed.
3. Pre-Production Sample (PPS)
The final sample approved before bulk production begins. This becomes the reference for quality control.
4. Size Set Sample
One sample per size to verify grading and fit across the size range. Essential for brands offering multiple sizes.
How Many Rounds Do You Need?
Most new brands need 2-3 fit sample rounds before reaching PPS approval. Complex designs may require more.
Cost Considerations
Each sample round involves pattern work, fabric, cutting, sewing and shipping costs. Budgeting for at least 3 rounds per style is recommended.
Tips for Efficient Sampling
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