Everything to Know About Workout Shirts for Men: Fit, Fabric & Function

A workout shirt does more than cover your torso. It plays a functional role in regulating body temperature, managing sweat, and supporting natural movement. Plus, the right fabric and fit can help keep muscles relaxed, allow for unrestricted motion, and reduce irritation caused by seams or fabric bunching.

For brands, this kind of premium clothing is a gateway to customer loyalty. If the shirt fits right, performs well, and holds up after multiple washes, the customers are likely to return for more.

This blog post is for anyone interested in creating high-quality, custom workout shirts for men. We’ll break down everything you need to know about fit, fabric, and apparel functionality, so you can make informed decisions and build something that athletes and casual gym-goers will actually want to wear.

But first, let’s understand:

Why Workout Shirts Matter More Than Ever?

Men’s activewear is no longer just about putting on an old t-shirt for the gym and calling it a day. Today, more and more individuals are investing in clothing that helps them move better and perform at their best, whether they’re hitting the gym, going for a run, or training at home.

What’s changed is not just the demand, but the mindset. 

Men now look for workout shirts that strike a balance between style and function. They want something that looks sharp enough for a casual outing but is technical enough for a high-intensity gym session.

That’s why expert clothing manufacturers and fitness brands focus on all essential details to craft the best design and fit for men's workout shirts.

Understanding the 3Fs (Fit, Fabric & Function)

 

1. Fit: How a Shirt Should Feel and Look

When it comes to men’s workout shirts, fit is all about performance, comfort, and confidence. A great fit allows for a full range of motion without feeling restrictive or baggy. 

Here's a breakdown of the fit types and important design details for workout shirts:

Types of Fits

• Slim Fit: Designed to follow the body’s natural shape without being too tight. It is ideal for athletic builds and activities where minimal fabric movement is needed. 

• Regular Fit: A balanced fit, not too tight, not too loose. It offers comfort and versatility for a wide range of body types and workouts. 

• Loose/Relaxed Fit: This fit is favored in activities like yoga or heavy lifting, where breathability and free movement are top priorities.

Design Considerations

• Sleeve Length: Short-sleeve workout shirts that stay in place are crucial during exercise sessions. For the safer side, consider offering sleeveless or long-sleeved workout shirts based on training and preference.

• Hemline (Drop-Tail, Curved, etc.): A drop-tail hem adds coverage during stretching or lifting. On the other hand, curved hems create a more athletic silhouette and help the shirt stay in place.

• Shoulder Seams: Raglan or offset seams are widely used in workout shirts for men. They reduce friction and improve mobility, especially for upper-body movements.

[Also Read: Types of Seams and Their Uses]

2. Fabric: What It Is Made of

   
   

Fabric is the foundation of any great workout shirt. It affects how a shirt looks, performs, feels, and holds up over time.           

Below are the different types of fabrics used in men’s activewear, along with key features brands should pay attention to when choosing fabrics.

Popular Fabric Options

• Polyester: A go-to in performance wear. It’s durable, lightweight, and dries quickly, perfect for high-sweat activities. However, it can retain odors if not treated with antimicrobial finishes.

• Cotton Blends: Softer and more breathable than 100% polyester, cotton blends offer comfort with a bit of performance. These are great for low-intensity workouts or hybrid casual-athletic wear, but they don’t wick moisture as effectively.

• Nylon: Known for being smooth, lightweight, and highly abrasion-resistant. It’s ideal for rugged workouts or outdoor training. 

• Bamboo or Modal: These eco-friendly fabrics are naturally breathable and soft on the skin. Bamboo is also naturally antibacterial. They aren’t very quick-drying, but they’re a great option for sustainable gear.

Moisture Management

• Sweat-Wicking Technology: Fabrics with moisture-wicking properties pull sweat away from the skin and move it to the fabric surface, where it can evaporate more quickly. 

• Breathability and Ventilation Zones: Mesh panels or laser-cut holes placed in high-sweat areas (like underarms or the back) boost airflow and help cool the body during workouts.

• Anti-Odor/Antimicrobial Finishes: Treatments that prevent bacterial growth help workout shirts stay fresh for longer. Especially useful for polyester-based garments, which can trap odor over time.

3. Function: Designed for Ideal Performance

   
   

Functionality is the key factor in workout shirts for men as well as women. Beyond fabric and fit, it’s the functional details that turn a basic workout shirt into true performance gear.Here are the most essential aspects to consider when working on the functionality:

Seam Construction

• Flatlock seams lie flat against the skin, reducing irritation and chafing. These are ideal for high-movement activities.

• Overlock seams are more common and cost-effective, but can create slight ridges.

• Bonded seams are glued instead of stitched, offering a sleek, minimal feel with no bulk.

  
  

Stretch and Recovery

A good workout shirt should move with the body. The 4-way stretch fabric expands both vertically and horizontally, supporting dynamic movements like squats, lunges, and overhead presses, without losing its shape afterward.

Thumbholes, Zip Pockets, Headphone Loops

Small additions like thumbholes on long sleeves, discreet zipper pockets for keys or cards, or loops to secure headphone cords to your men’s workout shirts can add a layer of practicality that users appreciate and remember.

Key Tips for Designing Custom Men’s Workout Shirts for Your Brand

Creating a high-performance workout shirt demands informed decisions based on the market and your brand identity. Whether you’re launching your first activewear piece or refining your current line, the steps below will help guide the process.

[Also Read: How To Design and Launch Your Fitness Clothing Line?]

Define your target audience clearly (athletes, gym-goers, or casual runners) so you can choose the right fabric and fit features that meet their expectations.

Align performance features with customer requirements. High-intensity users may want 4-way stretch, sweat-wicking fabrics, and flatlock seams, while casual wearers might prioritize softness, versatility, and relaxed fits.

Don’t ignore aesthetics because modern consumers want shirts that look as good as they perform. Pay attention to silhouettes, color palettes, body measurements, and branding details that align with your brand identity.

Always prototype before mass production. Samples help you test the fabric’s comfort, fit, moisture control, and durability in real workout conditions.

Conduct wear testing with real people. Feedback from athletes or fitness professionals highlights issues you may overlook, such as restricted motion, seam irritation, or breathability.

Use high-quality fabric swatches to make better decisions. Feel the difference between options and test for stretch, opacity, and drying time before finalizing materials.

Choosing the Right Custom Clothing Manufacturer

Partnering with an experienced custom clothing manufacturer is essential to design and deliver an excellent-quality product to your target audience. 

Work with Lydia Design Studio, a leading clothing manufacturer based in Atlanta, Georgia, with a strong track record in producing high-quality custom activewear, including workout shirts for men and other fitness gear.

We offer complete support throughout the process, from design consultation and fabric sourcing to prototyping, testing, and bulk production, ensuring your product meets market expectations.Book a free design consultation with us and build a successful product that performs, sells, and strengthens your brand reputation.