Sportswear has evolved significantly over the last 2 decades, with advancements in technology and design playing a pivotal role in how activewear is crafted.
One of the most notable innovations in recent years is the shift from traditional sewn garments to heat sealed, bonded sportswear. While both methods aim to provide comfort, durability, and performance, they cater to different needs and preferences.
Many high-end sportswear brands are using more bonding manufacturing techniques to provide a cleaner solution to machine stitched seams and construction.

What is Sewn Sportswear?
Traditional sewn sportswear refers to garments made using traditional stitching techniques. Fabric panels are joined together with thread, creating seams that hold the pieces together. This method has been used for centuries and is the most common way to construct clothing.
This method is fast and easy to learn with factories having teams of machinists that are trained and capable of stitching garments in this traditional fashion.
Advantages of Sewn Sportswear
- Durability: Well-stitched sportswear can withstand significant wear and tear, making it suitable for high-intensity activities.
- Cost-Effective: Sewing is a cost-efficient production method, resulting in more affordable sportswear options.
- Wide Availability: Since sewing is a traditional method, there are numerous manufacturers and designs to choose from and all factories offer stitched garments.
- Repairable: Damaged seams in sewn garments can often be easily repaired, extending the lifespan of the clothing.
Disadvantages of Sewn Sportswear
- Bulkiness: The seams in sewn garments can add bulk, which may be uncomfortable during certain activities.
- Chafing: Stitched seams can cause friction against the skin, leading to chafing during prolonged use.
- Moisture Retention: Seams can trap moisture, which may compromise comfort and performance.
What is Heat Sealed Bonded Sportswear?
Bonded sportswear, on the other hand, utilises advanced adhesive or heat-sealing techniques to join fabric panels without the need for stitching. This seamless construction method has gained popularity in recent years due to its sleek and innovative design.
Some suppliers and brands that specialise in bonded seam construction
One of the biggest heat-sealed tape providers is Bemis
Lucas Hugh is a premium activewear brand that uses bonding to create a futuristic look.
Arcteryx is a high-performance mountain wear brand that has their own factories to maintain the quality of their bonded technology.
GRVL is a cycling apparel brand that bonds many of their seams to create a finer, and softer seam.
Ardmel is one of the leading bonding machine suppliers
Advantages of Bonded Sportswear
- Seamless Finish: Bonded garments have a smooth finish, reducing bulk and enhancing comfort.
- Reduced Chafing: The absence of traditional seams minimises skin irritation, making it ideal for long workouts or endurance sports.
- Enhanced Performance: Bonded seams are often more flexible, allowing for greater freedom of movement.
- Lightweight: The bonding process eliminates the need for thread, resulting in lighter garments.
- Water Resistance: Bonded seams can be made waterproof, making them perfect for outdoor activities in wet conditions.
Disadvantages of Bonded Sportswear
- Cost: The advanced technology involved in bonding makes these garments more expensive. Factories that offer bonding usually only employ a limited number of staff to manufacture bonded seams with a few bonding stations compared to hundreds of sewing machines.
- Repair Challenges: Once damaged, bonded seams are harder to repair compared to sewn seams.
- Limited Availability: Bonded sportswear is less widely available and may have fewer design options. It’s also important to find a factory that specialises in this technique. At Blue Associates Sportswear we have witnessed samples and production from bonding factories that fall apart after washing.
- Quality: There are only a limited number of factories globally that really understand bonding and how to create long lasting garments. There are hundreds of factories with bonding machines and claim to produce quality bonded sportswear, however most won’t last or understand how to calibrate the machines or test the fabrics.
Key Differences Between Sewn and Bonded Sportswear
1. Construction Method
- Sewn Sportswear: Uses traditional stitching techniques to join fabric panels.
- Bonded Sportswear: Relies on adhesives or heat-sealing methods for a seamless finish.
2. Comfort and Fit
- Sewn Sportswear: May feel bulkier due to seams, which can lead to chafing during intense activities.
- Bonded Sportswear: Offers a smooth and sleek finish, enhancing overall comfort and reducing friction.
3. Durability
- Sewn Sportswear: Durable and repairable but may weaken over time as seams fray.
- Bonded Sportswear: Flexible and lightweight but can be harder to repair if damaged.
4. Design and Aesthetics
- Sewn Sportswear: Provides a traditional look with visible stitching.
- Bonded Sportswear: Features a modern, minimalist aesthetic with invisible seams.
5. Cost
- Sewn Sportswear: Generally, more affordable due to simpler manufacturing processes.
- Bonded Sportswear: More expensive, reflecting the advanced technology and materials used.
Choosing the Right Sportswear for Your Brands Needs
Your choice between sewn and bonded sportswear will depend on several factors, including your activity type, personal preferences, and budget.
When to Choose Sewn Sportswear
- Budget-Friendly Options: If you’re looking for affordable activewear, sewn garments are the way to go. The choice of factories are much wider and there is less development required to produce samples.
- High-Impact Activities: For sports that involve heavy-duty movements, the durability of sewn seams can be advantageous.
- Casual Wear: For day-to-day fitness activities or leisurewear, sewn sportswear provides comfort and versatility.
When to Choose Bonded Sportswear
- Performance-Focused Activities: If you’re into high-performance sports like running, cycling, or triathlons, the lightweight and seamless nature of bonded garments can enhance your performance.
- Outdoor and Water Sports: The waterproof capabilities of bonded seams make them ideal for swimming, hiking, or other outdoor activities.
- Style-Conscious Athletes: For those who value sleek, modern designs, bonded sportswear offers a contemporary aesthetic.
Innovations in Sportswear Technology
The evolution of sportswear isn’t limited to the sewing vs. bonding debate. Innovations like moisture-wicking fabrics, compression technology, and smart textiles are also shaping the future of activewear. Many manufacturers now combine sewing and bonding techniques to create hybrid garments that offer the best of both worlds.
Caring for Your Sportswear
Whether you opt for sewn or bonded sportswear, proper care is essential to maintain their longevity and performance.
Tips for Caring for Sewn Sportswear
- Wash Inside Out: Protect the seams by turning the garment inside out before washing.
- Use Mild Detergent: Avoid harsh chemicals that can weaken the threads.
- Air Dry: Prolong the life of your sportswear by air drying instead of using a dryer.
Tips for Caring for Bonded Sportswear
- Avoid High Heat: Excessive heat can damage the adhesive used in bonded seams.
- Hand Wash When Possible: This gentle method prevents damage to the bonded areas.
- Store Properly: Avoid folding bonded garments along the seams to prevent stress on the adhesive.
Understanding the difference between sewn and bonded sportswear is crucial in selecting the right gear for your athletic pursuits. While sewn sportswear offers durability and affordability, bonded sportswear stands out for its sleek design and performance benefits.
By considering your specific needs and preferences, you can make a choice that supports your fitness journey and enhances your overall experience.
Remember that if you do decide to create bonded sportswear, make sure the factory is a specialist and specify the fabrics and bonding tapes to confirm the long-term quality.
Obtain the settings required to bond your nominated fabrics together from the tape supplier and make sure the factory follows these instructions.
Test the seams for durability and wash any samples several times to make sure the bonding will last.
If you are looking to produce bonded or traditional sewn sportswear, then please get in touch.