The Real Reason Most Activewear Brands Stop at 2XL (And Why That's About to Change)

When a customer recently reached out, genuinely "made up" to discover our 6XL leggings comfortably fit UK sizes 28-32, it was more than just a sale for us at Hero’s Thread. It was a stark reminder of the widespread frustration and exclusion that plagues the activewear industry. Why is it that in 2025, finding functional, stylish activewear beyond a 2XL feels like searching for a needle in a haystack for so many? It’s a question that’s driven me, Danny, the founder of Hero’s Thread, since day one.

 

Most people assume it’s just about cost, or perhaps a lack of demand. But the truth, as I’ve learned navigating the murky waters of manufacturing and brand building, is far more complex, and frankly, often quite disappointing. Let’s pull back the curtain on why so many activewear brands draw an arbitrary line at 2XL, and how Hero’s Thread is determined to redraw it entirely.

 

The Myth of "Just Cost": It's More Than Just Extra Fabric

 

It’s the easiest assumption to make, isn't it? "Larger sizes just use more fabric, so they cost more to produce." While there's a kernel of truth to that – yes, a 6XL garment will, by definition, require more material than an XXS – this is a gross oversimplification of the problem. If it were purely about fabric, the price difference would be marginal, and brands would happily scale up to meet demand. But they don't, do they?

 

The reality is that the decision to stop at 2XL is often rooted in a combination of factors that go far beyond the simple material cost. It's about design complexity, manufacturing hurdles, and, dare I say it, a significant amount of outdated thinking and even a dash of pure laziness from some corners of the industry. It’s a convenient excuse, allowing brands to avoid the real work involved in true inclusivity.

 

The Technical Reality: It's Not Just "Making It Bigger"

 

Here's where the real complexity kicks in. You can’t just take a pattern for a size Medium and simply scale it up linearly to a 6XL. If you did, you’d end up with something that looks like it belongs on a cartoon character – arms that are too long, neck holes that gape, and shoulders that look like they’ve been stretched on a medieval rack. It would be an absolute shite fit, and frankly, an insult to the customer.

 

Pattern Grading: Proper pattern grading for larger sizes is an art form and a science. It involves understanding how the human body scales and changes shape across different sizes. It's not just about adding inches; it's about adjusting proportions, darts, seams, and curves to ensure the garment maintains its intended fit, support, and aesthetic integrity. A good 6XL activewear top needs to offer the same range of motion and comfort as a small, but it requires completely different proportional adjustments.

 

Fit Testing: This is crucial. You need real people, with real bodies across the entire size spectrum, to try on your prototypes. This means investing in diverse fit models, gathering their feedback, and iterating on designs. Many brands simply don't want to make this investment. They'll fit a size small and a size large, and then just hope their grading works for everything in between, and beyond. At Hero's Thread, we've gone to painstaking lengths to ensure our larger sizes don't just "fit," but truly flatter and support. My own experience building this brand, constantly tweaking designs, has shown me that this meticulous approach is the only way to genuinely serve our customers.

 

Construction: Sometimes, larger sizes require different construction techniques or reinforced stitching to provide adequate support and durability. A garment designed for a smaller frame might not hold up to the same stresses on a larger body without these considerations. Ignoring this leads to products that quickly fall apart, damaging brand reputation and customer trust.

 

The Manufacturing Maze: Supplier Limitations and MOQs

 

Even if a brand nails the design and grading, they then face the hurdle of manufacturing. Many factories are simply not set up to produce an extensive size range. They often specialise in certain size brackets, or their machinery and processes are optimised for more "standard" sizes (which, again, typically means up to 2XL).

 

Supplier Limitations: Finding manufacturers willing and capable of producing XXS to 6XL, particularly for performance activewear, is a monumental task. They might lack the experience, the diverse range of fit models, or the inclination to deviate from their established production lines. It's often easier for them to just say "no" to the broader size spectrum.

 

Minimum Order Quantities (MOQs): This is a huge one. Factories typically have MOQs per size. If a brand wants to produce 500 units of a particular design, they might need to order 50 units of each size. If they extend their range to 10 sizes (XXS-6XL), that's 50 units x 10 sizes = 500 units. But what if they perceive demand for a 5XL or 6XL to be lower than a Medium? They might be stuck with excess inventory for those larger sizes, which ties up capital and warehouse space. This risk aversion often leads them to simply cut off the larger sizes to minimise potential losses, even if the actual demand is there. It’s a vicious cycle born of perceived risk, not actual customer need.

 

My own quest to find manufacturers, especially for our tech pack t-shirts, often hit this wall. India and China offered some options, but always with that MOQ per size hurdle. It’s a financial gamble that many established brands, ironically, are too risk-averse to take. This is part of why we chose to work with print-on-demand technology. It allows us to offer our full size range without the traditional manufacturing barriers that prevent other brands from being truly inclusive.

 

The Mindset Problem: Brand Perception and Market Segmentation

 

This is perhaps the most insidious reason. Many brands, particularly those in the fashion-forward or "aspirational" activewear space, are still operating under an outdated and frankly discriminatory mindset. They believe that their brand image is tied to a certain body type, usually slender and athletic, and that offering larger sizes might "dilute" or "damage" that perception. It's a load of absolute bollocks, but it's a real factor in their decision-making.

 

Perceived Niche: Some brands genuinely believe that the market for larger sizes is too niche to bother with, or that consumers in those sizes aren't their "target demographic." This ignores the millions of people who are active, want to be active, or simply desire comfortable, well-fitting clothes for everyday life, regardless of their size. This is a massive oversight and a huge missed opportunity.

 

Marketing Inertia: It's easier to market to a perceived ideal body type. Their ad campaigns, social media, and even retail displays are all geared towards this narrow vision. Expanding sizes means rethinking their entire marketing strategy, potentially challenging their existing brand identity, and investing in new imagery and messaging. For many, it's just too much hassle.

 

What This Means for You: The Consumer Impact

 

For too long, this industry inertia has left countless individuals feeling excluded, frustrated, and even ashamed. It sends a message that if you don't fit into a 2XL, you're not worthy of quality activewear, or worse, not worthy of being active at all. This is not only untrue but deeply damaging.

 

Think about the customer who was "made up" by our 6XL leggings. Her reaction wasn't just about finding clothes; it was about finding validation, about feeling included, and about finally being able to participate fully in activities without the added stress of ill-fitting gear. It’s about being able to focus on their workout, not on whether their leggings are going to split. It's about confidence, comfort, and the freedom to just be.

 

The Path Forward: How Brands Like Hero’s Thread Are Changing This

 

At Hero’s Thread, we’re not just selling activewear; we’re challenging the status quo. Our journey, born from personal experience and a fierce determination to do things differently, is built on the principle that activewear should be accessible and empowering for everyone.

We're also proud to use recycled polyester, ensuring our commitment to inclusivity extends to the planet too. Our Hero's Thread Elite Performance Jersey, made from 100% recycled polyester with UPF 50+ and two-way stretch, is a prime example of this dedication across the board.

 

Our brand name, inspired by the myth of Theseus and Ariadne, symbolises finding your path through challenges. For us, that’s meant navigating the complexities of the activewear industry to create something truly inclusive. For you, it means having the thread you need to guide you through your own active journey, whatever your size or shape.

 

Closing:

 

The excuses for limited sizing in activewear are crumbling. The demand is unequivocally there, the technical solutions exist, and the mindset needs a drastic overhaul. At Hero’s Thread, we believe that true performance activewear is for every body. We're not just offering larger sizes; we're offering the same quality, the same support, and the same confidence to everyone.

 

Join us in demanding better from the activewear industry. Explore our range and find the perfect fit that empowers your heroic journey. Because at Hero’s Thread, we believe everyone deserves to feel like a hero, inside and out.