From Concept to Collection: Launching a Premium OEM Running Line

The Challenge

A US-based activewear startup approached us with an ambitious goal: launch a premium running collection in time for the spring season. They had strong branding and a clear customer profile, but no manufacturing relationships and limited experience in technical sportswear development.

Their requirements were demanding:

• 12 SKUs covering tops, shorts, tights, and a lightweight jacket
• Moisture-wicking and UPF 50+ fabrics throughout
• Reflective detailing for low-light visibility
• Full private-label packaging and hang tags
• Delivery within 16 weeks

Our Approach

Fabric & Material Sourcing

We opened our fabric library to the client, presenting over 30 performance fabric options. After testing samples in our in-house lab, we narrowed it down to two primary materials:

1. 88% Polyester / 12% Spandex four-way stretch for the base layers — offering excellent moisture transfer and a 200% stretch recovery rate.
2. Recycled nylon ripstop for the jacket shell — lightweight at 68 GSM with a DWR finish.

All fabrics were certified to OEKO-TEX Standard 100, meeting the client's sustainability requirements.

Pattern & Prototype Development

Our technical design team translated the client's mood boards and reference garments into original patterns. We produced two rounds of prototypes, iterating on:

• Flatlock seam placement for reduced chafe on long runs
• Waistband depth and internal drawcord routing
• Reflective tape integration without adding bulk

The client approved final samples after the second round — a faster-than-average cycle that saved two weeks.

Production & Quality Control

We ran a pilot batch of 50 units per SKU before committing to the full production run. Our QC team conducted:

• In-line inspections at fabric cutting, sewing, and finishing stages
• AQL 2.5 final inspection on the completed order
• Wash and colorfastness testing to ensure dye stability across 50 washes

Defect rate on the final shipment: 0.3%, well within acceptable tolerance.

The Outcome

The full 12-piece collection shipped in week 15 — one week ahead of schedule. The brand launched to strong sell-through in their first season, with the running tights and long-sleeve top becoming bestsellers.

"Cyclodry understood what we needed before we even had the vocabulary to describe it. The quality speaks for itself." — Founder, US Activewear Brand

Order volume: 4,800 units across 12 SKUs
Lead time: 15 weeks (1 week under target)
Defect rate: 0.3%