Sew Your Own Athletic Wear: Pattern Ideas and Fabric Tips

There’s something empowering about sewing clothing that supports your strength, movement, and confidence. I started going to the gym regularly almost two years ago, and lifting has done wonders for my energy and my “future-proofing”—I want to be the 90-year-old who gets off the floor with ease! And while functionality matters, you know I still want to look cute. Sewing my own activewear means I can get the colors I want, pieces that coordinate, and styles that suit my body and workouts.

My friends at Surge Fabrics* sent me two bundles of Activewear Fabric for me to sew up some new workout clothes. There was a yard and a half of each of the fabrics.  Today I’m walking you through two full mini athletic capsules—one for my daughter and one for me—made from these gorgeous deadstock bundles from Surge Fabrics, plus the patterns that brought everything together. Read on or watch here:

My Daughter’s Athletic Wear Capsule

I used one of the bundles Surge sent over to build a small but mighty capsule for my daughter—she’s a Summer, and these cool yellow and green tones lit her up. Each fabric behaved differently, so below is how I used each one.

Olive Active Knit

This fabric is perfect weight for leggings, shorts, or sports bras.  There was enough of this fabric for shorts (plus extra for a coordinating sports bra or fitted tank when I get around to it!  I used the Greenstyle Stride Leggings pattern (with pockets for her phone, key card, and campus essentials).  This pattern has a full butt option and a gusset that makes it fit great.

Striped Lime/Olive Knit

This fabric is great for sports bras, fitted tanks, or bold leggings but would also work beautifully for looser tees. From this fabric, I sewed the Greenstyle Tiny Tee Sewing Pattern with the open-back option so her future matching olive sports bra will peek through. This peak-a-boo back looks so cute on her.

Crepe-Textured Knit

The lovely yellow is light-to-medium weight crepe-textured knit that is lovely for jackets, tees, fitted tops, but not suitable for leggings. I used the Greenstyle Trail Jacket Sewing Pattern and made the half-zip version with kangaroo pocket. I finished it with a fun multicolor zipper.

Even with yardage constraints (1.5 yards each), the wide fabrics made everything work—including the jacket that typically calls for 2 yards.

My Athletic Wear Capsule

For my own bundle, I leaned into warm camel, ocean blue mesh, and a Southwestern-inspired stripe—all incredibly mix-and-matchable.

Ocean Blue Mesh

The mesh fabric is Best for breathable tops, layering pieces, or jacket panels, but way too sheer for leggings. I used the Greenstyle Boxy Tee Sewing Pattern to sew up a perfect dupe for a favorite store-bought athletic top. It has a modern, cropped, boxy silhouette with a fitted sleeve—great for layering.

Camel Active Knit

This fabric is a bit heavier and ideal for leggings, sports bras, tanks, or skorts. I sewed another pair of Greenstyle Stride Leggings for myself, this time making the cropped length. I could see skorts, tennis dresses, and fitted tops made from this hard-working fabric.

Southwestern Stripe Knit

The “wow” fabric of my capsule became another Greenstyle Trail Jacket Sewing Pattern for me. Even though we have the same jacket, the pattern has tons of views: (half-zip, full zip, tee version, rash guard version) making it different each time you make it. I omitted cuffs and simply hemmed the sleeves with my coverstitch for a sleek finish. Another fun, multicolored zipper finished it off. You could also use this fabric for leggings or tops.

Sewing Tips for Activewear

• A serger and coverstitch make things fast, but a regular sewing machine works too.
• Use a twin needle for hems if you don’t have a coverstitch.
• Choose stretch thread whenever possible—athletic wear needs durability and recovery.  And yes, use the stretch thread in your bobbin too for maximum stretch!
• If you’re new to knits, my Knit Sewing Essentials class is the perfect place to start. It covers everything you need to confidently sew tops, leggings, and more.

Final Thoughts

If you’ve been curious about sewing your own activewear—whether for the gym, walking the dog, or living your best athleisure life—these patterns are endlessly versatile and quick to sew. As we head toward the new year, it’s the perfect time to treat yourself to a cute, sporty capsule you’ll actually want to wear.

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