Vitalis Sport Switzerland: Supportive Sports Bras Built on Double-Knit Polyester
Vitalis Sport is a growing Switzerland-based activewear label whose supportive sports bras range now anchors its seasonal offer. When the design team planned a wider range with tighter launch dates, it needed a fabric partner able to guarantee construction consistency, documented performance and shade continuity across every production lot.
Vitalis Sport: reviewing the fabric swatch set for the supportive sports bras programme
The challenge
The main risk in the project was long transit times disrupting retail launch dates. The previous supply chain ran through a trading intermediary, so there was little visibility of the mill, no construction sheet and no test evidence behind the performance claims. Without that documentation the brand could not brief its retail partners with confidence.
The solution
We proposed a dedicated double-knit polyester programme built around air-freight staging for the first order and sea freight thereafter. Development started with A4 lab dips and a full construction sheet covering fibre content, GSM, width, stretch and recovery, and colour fastness. Only after the brand approved hand feel and performance targets did the project move to a pre-production lot for fit sampling.
Sample and fit approval for the double-knit polyester construction
Implementation
- Development: lab dips and physical samples in 5 working days.
- Approval: colour, hand feel and stretch signed off in two rounds.
- Bulk: consolidated dye lots to hold shade continuity.
- QC: inline inspection plus final random inspection before packing.
- Testing: AATCC 79 absorbency on every bulk lot.
Specification delivered
| Parameter | Value |
|---|---|
| Fabric | double-knit polyester |
| Weight | 260 GSM |
| Width | 160–170 cm |
| Stretch | 4-way, recovery above 92% |
| Certification | ISO 9001 mill quality system |
| Colour fastness | Grade 4 or above |
Results
The new double-knit polyester programme helped Vitalis Sport passed 50 wash cycles with no measurable colour loss. The supportive sports bras line launched on schedule, and wash durability, opacity and fit consistency all held up through the first retail season. The brand has since extended the programme into additional colours and styles.
“The development process was transparent from the first sample. We finally had the data we needed to brief our retail partners with confidence.” — Vitalis Sport Product Team
Inline inspection and packing before the supportive sports bras shipment
Key takeaway
Moving from a trading model to mill-direct development removed the hidden risks in the supply chain. With documented construction, controlled shade management and inline quality control, Vitalis Sport could concentrate on design and marketing instead of firefighting production issues.
