Summary
A European activewear brand faced rising plus-size demand and fit issues. EationWear delivered a repeatable XS–5XL solution with grading, fit testing, and bulk QC standards—consistent fit, faster development, fewer returns.
Can't meet the customer's demand for large-sized clothing? EationWear’s Full-Size Solution (XS–5XL)
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- Issue Time
- 2025/12/19 21:48:02
1. Customer Background
Our customer is a Europe-based DTC activewear brand focused on yoga and light training apparel (leggings, sports bras, shorts, and tops). The brand stands out in its local market with a clear positioning: inclusive sizing + premium fabric feel.
The team is lean but highly focused. They compete in the mid-to-premium price range, driven by social media and repeat purchases—especially among customers who want the same style and color offered across more body types.
2. The Challenge
As the brand scaled, plus-size orders increased quickly—but their supply chain hit a wall:
Their existing factory could only handle standard sizes (S–XL).
Plus sizes (2XL–5XL) are not solved by simply “scaling up”. When brands copy the same pattern logic, common issues appear:
-waistband rolling
-uneven tension around hips and thighs
-back-waist slipping down
-uncomfortable crotch depth and rise balance
-fabric sheerness when stretched (not squat-proof)
-Without a proven grading system and fit-testing workflow, sampling cycles became longer, launch windows were missed, and returns increased—hurting brand reputation and paid ads performance.
They urgently needed a long-term manufacturing partner who could deliver full-size coverage with consistent fit, fabric performance, and reliable lead times.
3. The Solution
EationWear provided a Full Size Range (XS–5XL) end-to-end delivery solution, including:
Professional grading + pattern re-engineering, not simple enlargement
Multi-body fit testing and key-point adjustments to ensure consistent wear experience across sizes
Fabric + construction optimization to support plus-size stretch, recovery, and durability
Flexible production and standardized QC, ensuring consistency from sample to bulk
The result: the customer achieved same collection, same colors, full size range from XS to 5XL, with a repeatable improvement loop.
4. Solution Details (How We Implemented It)
4.1 Building the Full-Size Spec Sheet & Pattern Strategy
We aligned on three fundamentals first: target customer, use scenario, and fit style (high-waist vs mid-waist, compression level, preferred inseam, and rise/crotch feel).
Then we built a complete size spec sheet and treated plus-size risk points as dedicated control items:
-waistband height + elastic rebound control
-hip and thigh tension curve
-crotch depth + front/back rise ratio
-squat-proof and opacity evaluation under stretch
4.2 Two-Round Fit Testing to Reduce Trial-and-Error
We used a faster, more controlled sampling rhythm:
Round 1: Fit skeleton approval (back-waist stability, crotch comfort, thigh pressure)
Round 2: Detail + mass-production readiness (waist construction, seam placement, stitch tension, topstitch and elastic control)
This ensured plus sizes fit correctly while standard sizes kept the same clean silhouette and premium look.
4.3 Fabric & Construction Optimization (Plus Size ≠ Just “Thicker Fabric”)
Based on the customer’s chosen fabric direction, we optimized for real wear performance:
-verified stretch recovery and opacity targets without changing the hand-feel
-adjusted waistband structure and stitch tension to reduce rolling/slipping
-reinforced high-friction areas (inner thigh, crotch) with durability-focused stitch settings
-delivered production standards: stitch density, seam allowance, elastic stretch ratio, and critical measurement tolerances
4.4 Bulk Production Delivery: Making It Repeatable
To prevent “great sample, inconsistent bulk,” we executed:
-key size inspections (e.g., M / XL / 3XL as representative checkpoints)
-feedback loop after delivery for continuous improvement in next runs
-labeling and packaging alignment (size labels, care labels, hangtags) to match the brand’s system and reduce fulfillment errors
5. Results & Impact
After implementation, the brand gained a stronger, more scalable supply foundation:
Size range expanded from S–XL to XS–5XL, enabling true “same style, same color, full sizing”
Plus-size related return/exchange rate decreased (customer feedback: ~25% lower)
Product development became more efficient (customer feedback: ~30% shorter development cycle)
Most importantly, the brand’s inclusive sizing promise became more credible, improving reviews, repeat purchases, and overall marketing performance
Note: These figures reflect the customer’s stage-based feedback and demonstrate the trend and method. Results vary by style, fabric, and sales channel.
6. Customer Testimonial
“We struggled to stabilize plus-size fits—either patterns shifted or quality wasn’t consistent. EationWear helped us build grading logic, fit testing workflow, and bulk production standards. Now XS to 5XL can deliver the same fit experience, and customer feedback is noticeably better.”
— Brand Product Manager / Sourcing Lead
7. Next Step
If you’re experiencing any of the following:
growing plus-size demand but unstable factory results
high return rates caused by fit issues in extended sizes
you want XS–5XL in the same styles and colors, but sampling takes too long
Reach out to EationWear. We can support you with a size spec plan, grading strategy, sampling roadmap, and bulk production delivery system—turning inclusive sizing into a real growth driver.
8. Summary
EationWear is a B2B activewear manufacturer specializing in high quality, flexible customization, and reliable delivery for growing brands. We don’t just “make plus sizes”—we solve the system behind it: fit consistency, wear comfort, fabric-construction matching, and bulk repeatability.
Whether you’re producing yoga wear, training apparel, or custom team/football kits, we help your products stand out—and support long-term brand growth with a scalable manufacturing partnership.
Plus-Size Inclusivity: Designed to accommodate sizes up to 4XL, ensuring a comfortable and supportive fit for a wide range of body types
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Plus Size Range: Available in sizes up to 6XL, these yoga sets are inclusive, catering to a variety of body types
Plus Size Range: Available in sizes up to 6XL, these yoga sets are inclusive, catering to a variety of body types
Plus-Size Inclusivity: Designed to accommodate sizes up to 4XL, ensuring a comfortable and supportive fit for a wide range of body types
。