Custom Functional Athletic Jackets & Recycled Outerwear
Shoulder-season training exposes outerwear to the worst combination for a factory: cold, sweat and repeated pack-and-wear cycles. A jacket that leaks at the seam or pills at the cuff fails the athlete before it fails the label.
Passion Activewear manufactures custom functional athletic jackets and outerwear for brands that want recycled-shell performance without compromise. We have built activewear since 1999 across 10 production lines with 150,000 pieces of monthly capacity, using recycled shell fabrics, PFC-free DWR finishing and YKK zips, with recyclable mono-material construction where possible.
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01
Recycled Shell Fabrics
We build the outer layer from recycled content so the performance story does not depend on virgin petroleum-based textile.
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PFC-Free DWR Water Repellency
Our durable water repellent finish sheds light rain without the persistent fluorocarbon chemistry many markets now restrict.
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YKK Zips & Sealed Seams
Reliable YKK hardware and optional sealed seams keep the weather out at the points that fail first on cheap outerwear.
What We Manufacture in This Category
- Carbon Neutral Sportswear — recycled sportswear with documented material sourcing and cutting data.
- Core Basics Jumpsuits — one-piece jumpsuits and unitards in organic and recycled blends.
- Organic Cotton Hoodies & Joggers — certified organic cotton fleece sets with brushed-back softness.
- Recycled Athletic T-Shirts — rPET performance tees as the volume entry to a recycled range.
- Sustainable & Renewable Pants & Shorts — bio-based and renewable-fibre bottoms for training and casual wear.
Hot-Selling Functional Athletic Jackets & Outerwear
The outerwear styles performance brands request most. Send us your target shell weight, membrane and colour, and we produce the run with PFC-free DWR and YKK hardware as standard.
WOMENS Zip Cropped Vest
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WOMENS Insulated Primaloft Workout Jacket
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WOMENS Run Jacket
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Functional Athletic Jackets & outerwear
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Fabric & Construction Engineering
Outerwear is where recycled content is hardest to make perform, because the shell has to block wind and water while the membrane has to let vapour out. Our standard build pairs a recycled face fabric with a compatible breathable membrane and seals the seams that see the most flex.
- Main Fabric
- Recycled polyester ripstop shell, 70–160 gsm, with compatible breathable membrane
- Alternative Fabrics
- Recycled soft-shell, recycled woven liner, and mono-material construction options
- Moisture Management
- PFC-free DWR exterior with breathable membrane for vapour transport during training
- Printing Techniques
- Heat transfer, screen print, and silicone print on compatible shell panels
- Embroidery
- Multi-head embroidery for logos on low-stretch yoke and chest areas
- Hardware
- YKK zips, recycled-content trims, storm flaps and bartack at stress points
- Size Range
- Kids (XS–XL), adult (XS–5XL), men’s and women’s grading, custom size charts
- Quality Standard
- In-line inspection at every stage plus AQL 2.5 final random inspection
The outerwear build details
- Sealed and taped seams at shoulders and underarms where flex opens the path for water.
- PFC-free DWR applied to the recycled shell for light-rain repellency without restricted chemistry.
- YKK zips specified throughout, with storm flaps on the main opening.
- Mono-material construction considered on select styles to support end-of-life recycling.
- Reinforced cuff and hem edges that resist the curl cheap outerwear develops after washing.
For performance and outdoor brands: we can build a jacket and a matching vest or shell from the same recycled fabric and membrane, so a coordinated outerwear range ships colour-matched and weather-tested to one standard.
Why Brands Source Recycled Outerwear From Us
Recycled shell that still performs in weather
The usual objection to recycled outerwear is that it loses water repellency or breathability. Our PFC-free DWR and tested membrane pairing keeps the performance close to virgin shell, which is what lets a brand make the swap without a complaint spike.
One facility, audited environmental controls
Because the whole jacket is made on our own lines, the recycled content and the finishing chemistry are controlled in one place. That coherence is what makes the documentation simple for your retailer, and it is what lets the same standard carry from the first shell to the last liner.
Capacity for a coordinated outerwear drop
With 10 production lines and 150,000 pieces of monthly capacity, a jacket launch can include vests, liners and matching shells in one programme. Our 7–15 day sampling window lets you validate the membrane and fit before bulk.
Customization Options
- Shell weight: choose ripstop, soft-shell or woven liner by climate and use.
- Membrane: breathable, windproof or light-rain rating per your training context.
- Finish: PFC-free DWR as standard, with alternative repellents on request.
- Hardware: YKK zips, recycled-content trims and storm flaps throughout.
- Colourways: matched to Pantone or your physical swatch for batch consistency.
- Print & logo: heat transfer, screen print and embroidery on compatible panels.
- Packaging: recycled polybags and FSC cartons available on request.
- Documentation: recycled-content and finishing records packaged with the order.
Order Information at a Glance
| Item | Standard Terms |
|---|---|
| Minimum order quantity | 1,000 units per style per colourway |
| Sampling | 7–15 business days after design confirmation; sample cost refundable against bulk order |
| Bulk production | 25–45 business days after deposit and pre-production sample approval |
| Peak season (Q3–Q4) | 45–60 business days; advance planning recommended for season-start deadlines |
| Payment terms | 50% deposit to start production, 50% before shipment; T/T and L/C accepted |
| Incoterms | EXW factory, or FOB / CIF on request |
| Quality assurance | In-line inspection plus AQL 2.5 final random inspection before packing |
| Monthly capacity | 10 production lines, 150,000 pieces monthly capacity |
Frequently Asked Questions
Does recycled shell perform as well as virgin polyester?
For shoulder-season training, yes. Our recycled ripstop shell paired with a breathable membrane keeps water repellency and vapour transport close to virgin fabric, so the swap does not show up as a performance complaint.
What does PFC-free DWR actually protect against?
It sheds light rain and road spray without the persistent fluorocarbon chemistry many markets now restrict. For heavy downpour use we recommend a taped-seam shell, which we also build.
Can you make mono-material recyclable jackets?
On select styles we build from a single fibre type to support end-of-life recycling, and we flag these in the specification. Some membranes complicate that, so we discuss the trade-off during development.
What is the minimum order for a jacket style?
Our standard MOQ is 1,000 units per style per colourway. Coordinated drops with vests or shells share development, so the per-style cost stays manageable.
How long from sample approval to finished goods?
Bulk production runs 25–45 business days after deposit and sample sign-off, stretching to 45–60 in the Q3–Q4 peak. For a season launch we recommend confirming the order by early Q2 so the timeline protects your date.
