Short version: At a 100–300 piece run, expect ~US$6–12 per legging and ~US$4–8 per bra ex-works. A realistic first run lands at US$3,000–10,000 all-in (samples + bulk + branding + freight).
Per-unit garment cost (ex-works)
This is the factory price per piece, before shipping and duties. It drops with volume and rises with fabric weight, features (pockets, zips, bonding) and finish.
| Item | 100–300 pcs | 1,000+ pcs |
|---|---|---|
| Seamless leggings | US$7–12 | US$5–8 |
| Sports bra | US$4–8 | US$3–5 |
| Matching set (bra + leggings) | US$11–18 | US$8–12 |
| Shorts / biker shorts | US$5–9 | US$4–6 |
Add roughly US$0.30–1.50 per piece for logos (heat-transfer, silicone, embroidery), woven labels, hangtags and polybags.
Sample & development costs
- Development sample: ~US$30–80 per style (often credited against bulk).
- Custom fabric / Pantone match: sometimes a small fee or higher MOQ per color.
- Rounds: budget for 1–2 sample iterations to nail fit.
A realistic first-run budget
Example: 2 styles, ~100 pcs each, with branding and air freight.
| Line item | Estimate |
|---|---|
| Samples (3–4 rounds across 2 styles) | US$200–400 |
| Bulk: ~200 pcs total | US$1,800–3,600 |
| Logos, labels, hangtags, polybags | US$150–400 |
| Freight (air) + duties | US$400–1,200 |
| Typical first run | US$3,000–6,000 |
Add a website (US$0–500 on Shopify) and launch marketing (US$1,000–3,000) and you have your true day-one number.
Where brands waste money
- Ordering too many SKUs at once instead of testing 2–4 hero styles.
- Trading-company markups (you pay a middleman, not the maker).
- Skipping samples and paying for it in returns.
- Over-ordering before a style is proven.
FAQ
How much to manufacture a pair of leggings?
About US$7–12 per unit at 100–300 pcs; US$5–8 at 1,000+.
Realistic first-run budget?
US$3,000–10,000 all-in depending on styles, customization and freight.