Designing a great, supportive sports bra involves more than just combining supportive materials and stylish shapes. A high-quality sports bra should provide comfort, control, and a flattering fit, catering to various body types and activity levels. Here’s an in-depth guide to designing an exceptional sports bra that delivers on both functionality and style, with insights into key design elements, fabric choices, construction techniques, and the importance of testing.
At Blue associates Sportswear, we have been designing and developing sports bras for the last 20+ years and so think we know a thing or two about how to create a leading bra. Our most recent project was tested at #1 for support and comfort.
1. Understand the Purpose: Support, Comfort, and Style
The foundation of designing a great sports bra starts with understanding its purpose. Sports bras are more than just pieces of athletic wear; they’re essential for minimising movement, reducing discomfort, and providing stability during physical activity. Women rely on them for everything from high-impact activities like running and jumping to low-impact exercises like yoga or stretching. A good design should address these needs:
- Support: A great sports bra limits breast movement during exercise, reducing strain and potential long-term health issues.
- Comfort: Sports bras should be snug without being restrictive, with smooth seams, soft materials, and breathable fabrics.
- Style: Modern sports bras must also look good, as women often wear them solo or as part of a layered outfit.
By balancing these elements, you’ll create a sports bra that customers want to wear for both functionality and aesthetics.
2. Define the Activity Levels: Low, Medium, and High Impact
Sports bras vary significantly depending on the activity level they’re designed to support. It’s essential to understand the three main categories:
- Low Impact: Designed for activities like yoga, stretching, and walking. These bras offer light support with soft fabrics and often have thin straps and a flexible fit.
- Medium Impact: Suitable for cycling, hiking, or strength training. They offer moderate support and may include wider bands, thicker straps, and added structure.
- High Impact: Made for running, jumping, and high-intensity workouts. These bras offer maximum support, often featuring encapsulation or compression designs to minimise movement. Movement needs to be restricted vertically as well as horizontally and therefore special support and design features will need to be added to help achieve this.
For a well-rounded line, consider designing sports bras that cater to each impact level to meet the needs of a broad audience.
3. Choose the Right Fabric for Performance and Comfort
Selecting the best fabric is a critical step in sports bra design. The ideal fabric should be breathable, moisture-wicking, durable, and have stretch and recovery to keep the bra in shape. If you need help sourcing performance fabrics, then please see our guide here.
Key Fabric Characteristics:
- Moisture-Wicking: Sweat-wicking fabric pulls moisture away from the skin, keeping the wearer dry and comfortable. Polyester blends are common for this purpose but there are some sustainable fabrics that are also suitable.
- Breathability: Mesh panels and lightweight fabrics enhance airflow, preventing overheating during workouts.
- Stretch and Recovery: Fabrics with elastane or spandex provide stretch and allow the bra to conform to the body while returning to its original shape after wear. Note that the percentage of stretch doesn’t always represent the power of the stretch. The quality of the stretch fibre can effect how powerful the fabric recovers and its important you select a fabric with enough stretch but also power to recover after it’s stretched. Using a fabric with too much stretch and not enough power wil result in lower support.
- Softness: For added comfort, choose fabrics with a soft hand-feel, such as brushed blends.
Each sports bra style may benefit from different combinations of fabrics. For example, high-impact bras may need denser, more supportive materials, while low-impact bras can use lighter, softer fabrics. These bras will also potentially need areas that stretch or restrict stretch in different areas too.
4. Select a Supportive and Comfortable Construction Style
The construction style of a sports bra directly impacts its support level and comfort. There are two main construction types:
- Compression Bras: These bras compress the breasts against the chest to restrict movement. They’re ideal for small to medium busts and are often used in medium to high-impact bras.
- Encapsulation Bras: Encapsulation bras have separate cups that support each breast individually. They’re better suited for larger busts, as they provide support without excessive compression.
Hybrid Construction
Many modern sports bras use a hybrid of both compression and encapsulation to offer versatile support, particularly for high-impact activities. A hybrid style can combine the best of both worlds, providing high support without compromising comfort.
5. Consider the Band and Straps
The band and straps are the foundation of any good sports bra, as they carry most of the support. They should be sturdy yet flexible, offering support without digging into the skin. You will need to consider the shape, length and stretch of these depending on the end use and target consumer.
Band Design:
- Width: A wider band provides more stability, especially for larger busts and high-impact activities. A narrower band may be suitable for low-impact activities.
- Adjustability: Adjustable bands with hook-and-eye closures allow for a custom fit and make the bra more versatile, especially for women with fluctuating bust sizes.
- Elasticity: The band should have the right amount of elasticity—firm enough to stay in place during movement but stretchy enough to avoid discomfort.
Strap Design:
- Width and Placement: Wide straps help distribute weight evenly and reduce strain on the shoulders. Racerback designs or cross-back straps provide better support by redistributing weight.
- Adjustability: Adjustable straps allow users to customize the fit to their body. While not necessary in all bras, they add versatility, particularly for larger bust sizes.
- Padding: For added comfort, consider padding in the straps to prevent them from digging in, especially in high-support bras.
These elements should work in harmony to ensure that the bra stays securely in place, even during intense movements.
6. Incorporate Design Elements for Comfort
Comfort is one of the most crucial aspects of any sports bra, and small design choices can significantly impact the wearer’s experience.
Seams and Stitching
- Flat Seams: Flat seams reduce friction and prevent chafing. Avoid bulky stitching, which can create pressure points, especially in high-impact bras.
- Bonded Seams: Some sports bras use bonded seams, where fabric edges are heat-sealed rather than sewn, creating a smoother, more comfortable edge. Bonded seams tend not to stretch as much eiether so this could be a negative or positive solution depending on where the seam is placed.
Inner Linings and Padding
- Mesh Linings: A mesh lining adds breathability and moisture control.
- Removable Pads: Many sports bras include removable pads, allowing users to adjust the bra’s shape and support according to their preference. Make sure the padding is easy to remove and insert, and consider secure pockets to prevent the pads from shifting during wear. Many cheap sports bras have pads that most women remove as they fold, crease and rotate inside the lining of the bra and therefore look unsightly.
Tag-Free Labels
Tags can irritate sensitive skin during movement. Consider designing sports bras with tag-free labels, using printed or heat-transferred labels instead.
7. Design for Style and Versatility
Today’s sports bras often double as standalone tops, so style is a key component. A stylish design can make the difference between a bra that’s worn only for workouts and one that’s worn regularly and is on show.
- Silhouette: Popular styles include racerback, strappy, scoop neck, and high-neck designs. Offering a variety of silhouettes provides options for different style preferences.
- Colors and Patterns: Bright colors, bold patterns, and unique prints add personality. Neutral colors, like black and gray, are versatile and easy to pair with other activewear.
- Back Detail: The back of a sports bra is a great place to add design details, such as strappy designs, mesh panels, or cutouts.
Consider designing multiple collections to cater to different preferences, from minimalist designs to bold, fashion-forward options.
8. Test for Fit and Performance
Before finalizing a sports bra design, it’s essential to test it with real users to ensure it delivers on comfort, support, and durability. Here’s how to test effectively:
- Fit Testing: Try the bra on different body types and sizes to ensure that the fit is comfortable and secure across a range of shapes. Work out how you are going to size these, either by S, M , L etc or cup size.
- Movement Testing: Have users test the bra during various activities, from running to yoga, to see how well it controls movement and stays in place. Some test houses and univercities will conduct these tests and compare them to other bras they have tested. We have used the University of Portsmouth to conduct testing in the past who are excellent (in our opinion)
- Wear and Wash Testing: A high-quality sports bra should maintain its shape and support after repeated washing and wearing. Make sure the fabric and construction can withstand frequent use.
Feedback from testers can provide invaluable insights, allowing you to make necessary adjustments before the final production stage.
9. Focus on Sustainability
Sustainability is an increasingly important factor for consumers, and designing an eco-friendly sports bra can help meet this demand. Look for ways to reduce environmental impact:
- Eco-Friendly Materials: Consider using recycled polyester, Bamboo, or other sustainable materials.
- Ethical Production: Partner with factories that adhere to fair labor practices and ethical working conditions.
- Recyclable Packaging: Use minimal and recyclable packaging to reduce waste.
By prioritising sustainability, you’ll not only create a responsible product but also attract eco-conscious customers.
10. Gather Feedback
Designing a great performance sports bra is often an iterative process. After launching, gather feedback from customers to learn what works well and where there’s room for improvement. Customers may provide insights into fit, comfort, style, and durability that you can use to refine future designs.
Creating a great sports bra requires balancing support, comfort, and style while meeting the needs of different body types and activity levels. By carefully selecting fabrics, incorporating thoughtful design elements, and testing extensively, you can create a sports bra that’s not only functional but also attractive and versatile. Focus on quality construction, customer feedback, and a commitment to sustainability to design a sports bra that stands out in a crowded market.
If you are looking to design and produce a performance sports bra, please get in touch.
