Sew Now: Summer Activewear in Poly Spandex Knit

Sew Now: Summer Activewear in Poly Spandex Knit

Published by NannetteD on 17th Feb 2026

Activewear is one of the most satisfying things to sew because you’ll actually wear it—year-round. And sewing it now means your go-to pieces are ready for spring break, warm-weather trips, and those first sunny weekends (without the last-minute scramble).

These tips are to help you create a coordinated, boutique-looking activewear set using custom printed Poly Spandex 4-way Stretch Knit. Below you’ll find practical, sewist-tested tips for working with poly spandex (needles, stitches, elastic, and hems), plus a simple “build” approach for leggings/bike shorts + a matching top. The best part is choosing an artist-designed print that makes your handmade set feel truly one-of-a-kind.

Materials + Tools

  • Fabric: Polyester Spandex 4-way Stretch Knit (yardage varies by pattern; see typical ranges below)
  • Thread: Polyester thread
  • Needle: Stretch needle (recommended for spandex knits)
  • Notions (as needed): 3/8"–1/2" swim elastic (for swim edges), waistband elastic (optional), clear elastic (optional for stabilizing)
  • Tools: Clips (preferred), scissors or rotary cutter, ruler/measuring tape, marking tool, iron (low heat), walking foot (optional but helpful)

Fabric Specs (Polyester Spandex 4-way Stretch Knit)

  • Content: 83% Polyester / 17% Spandex
  • Weight: 6.6 oz/yd2
  • Printed Fabric Width: 58"
  • Care: Machine wash and dry
  • Best For: Leggings, bike shorts, sports bras, swimwear, rash guards, athleisure

Typical Yardage Ranges (Quick Planning Guide)

  • Leggings: 1.5–2.25 yards
  • Bike shorts: 1–1.5 yards
  • Sports bra: 0.5–0.75 yard
  • Rash guard: 1.25–2 yards
  • Bikini (lined): 0.75–1.25 yards total (depends on coverage + lining approach)

Note: Always confirm yardage using your specific pattern and size range.

Step 1: Choose Your Pattern (Start Simple)

If you’re new to sewing activewear, start with a pattern you trust and keep the first version straightforward. A great “set” starter combo is:

  • High-waist leggings or bike shorts
  • A simple sports bra or cropped tank

If you’re sewing for water days, consider adding a rash guard or making a lined swim top/bottom.

Step 2: Build a Coordinated Print Plan (So It Looks Boutique)

The easiest way to make handmade activewear look elevated is intentional coordination. Use one print as the statement and one as the supporting player.

  • Hero print: leggings or bike shorts
  • Coordinate print: bra, waistband, straps, bindings, side panels, or pockets
  • Optional “bridge” print: if you’re sewing multiple pieces for travel/spring break

Featured Fabric Idea: We've selected "Sayulita" in Ocean Dream from the "Authenticity" collection by J Luna Designs. This elegant abstract design custom prints by the yard on any base fabric you choose so that you can choose your favorite, plus print it by the yard for apparel

Step 3: Before You Cut (3 Quick Checks)

1) Stretch + recovery
Stretch a scrap and let it relax. Good recovery helps your garment keep its shape (less baggy knee, less stretched waistband).

2) Stretch direction
For most leggings and fitted swim, you generally want the greatest stretch to wrap around the body for comfort and mobility. Always follow your pattern’s stretch requirement first.

3) Print placement
Bold prints look great along long lines (outer thigh, calf, sleeves). Smaller-scale prints and coordinates can look smoother at high-stretch curve areas.

Step 4: Set Up Your Machine (No Serger Required)

Needle: Start with a stretch needle. If you get skipped stitches, switching needle type/size is often the fastest fix.

Use a stretch-friendly stitch:

  • Stretch/lightning bolt stitch
  • Narrow zigzag
  • Triple stretch zigzag (great for high-stress seams)

Feeding tip: Don’t pull the fabric while sewing. If seams look wavy, slow down and use a walking foot if you have one.

Step 5: Sew Your Set (Simple Build Order)

Leggings / Bike Shorts (typical order):

  1. Sew the rise seams
  2. Sew inseams
  3. Sew the crotch seam and reinforce it with a second pass
  4. Attach waistband (wide self-fabric waistband or elastic option)
  5. Hem using a stretch stitch or twin needle

Sports Bra / Crop Top (typical order):

  1. Sew main seams
  2. Add band/underbust elastic as directed by your pattern
  3. Finish neckline/armholes (binding or elastic finish)

Easy upgrade: Add a phone pocket to the outer thigh or side panel—it’s one of the most “wear-it-every-day” details you can sew.

Optional: Reversible Swim (Premium Finish + Mix-and-Match)

If you’re sewing swim, reversible construction is a great next step. Fully lined pieces feel more finished and give you more outfit options.

  • Premium finish: lining improves coverage and creates a clean interior
  • More ways to wear: flip the top, the bottom, or both to mix prints/colorways

Tip: Choose finishes that look clean on both sides (enclosed elastic and consistent topstitching).

Step 6: Press + Finish (The “Ready-to-Wear” Step)

  • Press seams gently (low heat) as you go
  • Topstitch consistently for a polished look
  • Test stretch at hems/waistband before calling it done

Recommended Sewing Pattern Companies (Activewear + Swim)

Not affiliated—just reliable options many sewists enjoy:

  • Jalie
  • Greenstyle Creations
  • Patterns for Pirates
  • Closet Core Patterns
  • Megan Nielsen Patterns
  • Cashmerette
  • Seamwork

Ready to make it truly one-of-a-kind?

The magic of custom activewear is the print. Choose an artist-designed collection, then build a coordinated capsule that looks intentional from every angle—leggings + sports bra, shorts + rash guard, or reversible swim pieces for travel and summer fun!

For even more flexibility and creative fun, every design in the online catalog prints on 15+ base fabric options that are perfect for soft and breezy summer tops, dresses, and beach cover ups to matching canvas-weight options to make matching totes and duffle bags for your active lifestyle!

Browse fabrics: View all designs
Browse designers: Shop independent designers

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How To Order Fabrics on The Textile District:

Each colorway image represents 27" of printed fabric and clicks through to the product page for easy ordering:

  1. Choose a design (or shop by designer collection)
  2. Select your base fabric (choose Polyester Spandex 4-way Stretch Knit for activewear)
  3. Select the color way you wish to print (click the icon)
  4. Enter the quantity you need (yards)
  5. Add to cart to order

If you need help choosing the best base fabric option for your project, please send us a note or give us a call. We'd love to hear what you’re making!

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