Leggings Manufacturer in the USA — Custom, Yoga, Gym &
Private Label Leggings Built for Your Brand
Rajco USA is a factory-direct legging manufacturer based in Brooklyn, New
York — producing custom leggings, yoga leggings, and private label activewear
for US brands since 1935. From high-compression workout leggings to buttery-
soft everyday styles, every pair we manufacture is built to your exact
specification — right fabric, right fit, right finish.
The US leggings market is valued at over $40 billion and growing at nearly 7% annually — and it shows no sign of slowing down. From gym floors to grocery runs, leggings have become the most versatile garment in the American wardrobe.
If you’re building a leggings brand, expanding an activewear line, or sourcing high-performance leggings for your fitness label, you need a manufacturer with the technical depth, production scale, and US-market understanding to get it right.
That’s Rajco USA – a leggings manufacturer with 90+ years of apparel manufacturing expertise, a 6,000+ employee production facility, and a Brooklyn, New York office that keeps your project US-coordinated from start to finish.
Why US Brands Choose Rajco USA as Their Legging Manufacturer
We’re not new to this. Since 1935, Rajco USA has manufactured performance apparel for sports brands, fitness labels, and global retailers. We bring that same institutional knowledge — plus modern fabric technology and full custom development — to every leggings order we produce.
Here is what separates us from other leggings manufacturers:
90+ Years of Performance Apparel Manufacturing:
Three generations of manufacturing expertise. We’ve refined every part of the production process — from pattern grading to flatlock stitching — so your leggings arrive exactly as designed, every time.
Full Custom Development, No Minimums on Creativity
Your design. Your fabric. Your waistband height. Your pocket configuration. Your logo placement. We manufacture to your exact specifications — not a pre-existing template. Our cut and sew manufacturing team handles the full technical build.
Performance Fabrics That Actually Perform
Every fabric we use is tested before it reaches production. Squat-proof. Four-way stretch. Moisture-wicking. Compression-ready. We source the materials that your US customers demand from their activewear.
Private Label Ready — Your Brand, Our Manufacturing
Whether you’re launching your first leggings line or scaling an established collection, our private label manufacturing service covers design, production, custom labels, hang tags, and branded packaging – all under one roof.
Sustainable Options for Eco-Conscious Brands
Over 57% of activewear brands are now adopting recycled or sustainable materials to meet US consumer expectations. Rajco USA offers recycled polyester, OEKO-TEX-certified fabrics, and sustainable manufacturing practices across all leggings styles.
Leggings Styles We Manufacture
Rajco USA produces every major leggings category demanded by today’s US activewear and fashion market:
Ready to Build Your Leggings Line?
Over 90 years. Thousands of styles manufactured. Brands from New York to Los Angeles to Dallas — all trusting Rajco USA to build their activewear.
Our Custom Leggings Manufacturing Process
Every leggings order at Rajco USA follows a proven, transparent process — no surprises, no shortcuts.
Brief & Consultation
Share your vision: style category, target customer, preferred fabrics, design references, and price point. Our
US-based project coordinator reviews your brief and maps the production plan.
Tech Pack Development
No tech pack? Our Sportswear Tech Pack service builds your complete technical documentation — construction specs, material callouts, measurement charts, stitching details — before sampling begins.
Fabric Selection
We match your design brief to the right performance fabric. Recycled blends, compression knit, buttery nylon,
mesh — our sourcing network covers every material US leggings brands require.
Sample Production
Physical fit samples are produced and shipped for your review. Wear them. Work out in them. Test the
waistband, the inseam, the squat-proof rating. We revise until the sample matches your brief exactly.
Bulk Production & QC
Once samples are approved, full production begins with systematic quality checks at every stage — cutting
accuracy, seam strength, flatlock consistency, waistband alignment, and color accuracy.
US Delivery
We ship all orders directly to US addresses via DHL Express — the world’s
most trusted international shipping network. Every shipment includes full
commercial documentation, end-to-end tracking, and dedicated import support.
Leggings Fabrics We Work With
| Fabric | Performance Properties | Best For |
| Polyester/Spandex Blend | Moisture-wicking, durable, shape retention | Gym, athletic leggings |
| Nylon/Spandex Blend | Ultra-soft, squat-proof, premium feel | Yoga, high-end fashion leggings |
| Compression Knit | Graduated support, recovery | Compression, running leggings |
| Recycled Polyester | Eco-friendly, same performance as virgin poly | Sustainable activewear brands |
| Fleece-Lined Knit | Warmth retention, soft interior | Thermal, winter leggings |
| Seamless Knit | No seams, second-skin comfort | Seamless, yoga, loungewear |
| Cotton/Spandex Blend | Breathable, casual comfort | Everyday, loungewear leggings |
What US Brands Get With Rajco USA
Working with Rajco USA as your leggings manufacturer means:
Who We Manufacture Leggings For
Rajco USA’s leggings manufacturing serves US brands across every category:
- Women’s activewear and athleisure brands
- Yoga studios and wellness brands launching merchandise
- DTC eCommerce activewear labels
- Gym wear and fitness apparel startups
- Boutique fitness and studio brands
- Sports teams and athletic programs
- Influencer-led fashion and fitness brands
- Wholesale activewear suppliers
Frequently Asked Questions
What is the minimum order quantity (MOQ) for custom leggings?
Rajco USA works with brands at various order scales — from startup first runs to large-scale bulk production. Contact us to discuss your specific MOQ requirements and get a tailored quote.
Do you manufacture yoga leggings specifically?
Yes. Yoga leggings are one of our most requested styles. We manufacture them with four-way stretch fabrics, minimal seaming, high waistbands, and optional side pockets — built for the US yoga and wellness market.
Can you produce printed or sublimated leggings?
Absolutely. Our sublimation printing team produces full all-over prints with color accuracy and wash durability. Perfect for brands with bold, signature designs.
How long does custom leggings manufacturing take?
From approved tech pack to US delivery: typically 45–75 days depending on style complexity, fabric availability, and order size.
Do you offer private label leggings manufacturing?
Yes — complete private label manufacturing including your brand’s labels, hang tags, care tags, and custom packaging.
Can you manufacture sustainable leggings?
Yes. We offer recycled polyester blends and eco-conscious production options as part of our sustainable clothing manufacturing capabilities.
Do you offer size-inclusive leggings manufacturing?
Yes. We grade patterns from XS through 4XL to serve the US market’s growing demand for inclusive sizing across activewear.