Full-Length Activewear Bodysuit

A bodysuit costs $17-32 landed. Affordable China cotton jersey scoop neck: ~$17 → $70-$87 retail. Premium Portugal GOTS cotton rib square neck: ~$32 → $127-$159 retail. The snap crotch adds $2.50-4.00 CMT over a standard jersey top.

A bodysuit has a snap-close crotch gusset allowing bathroom access without removing the garment, and is typically made from jersey fabric for everyday wear. A leotard has a fixed crotch (no snap) and is made from performance lycra or jersey for dance, gymnastics, or stage use. From a manufacturing perspective: same factory, same fabric system, different crotch construction.

KAM heavy-duty snap -- specify by name on the tech pack. Minimum 15N pull force. Three snaps is the commercial default. Available in plastic (KAM standard) or metal (premium). Specify colour (gold, silver, black, or colour-match to fabric) on the tech pack. Do not accept substitution to a light press stud -- it will fail in wear within weeks of regular use.

Yes. An unlined gusset is not a commercial bodysuit. The gusset must be double-layered (outer + lining, same or softer fabric), cut separately, and sewn between the crotch layers. Minimum gusset width 8cm at its widest point. The lining fabric can be the same jersey as the body or a softer cotton if the outer is a rough-textured rib.

Crotch depth must be determined by fit trial on a live body across the full size range -- not a dress form. A dress form does not sit, walk, or move. The crotch extension grading (the extra length added per size for the crotch panels) must be validated separately from the body grading. A bodysuit that fits correctly at size S but is too short at size L or XL is a grading error.

Cotton jersey (180-200 GSM) for the most commercial and accessible version. Ribbed cotton/spandex (200-280 GSM) for the strongest DTC aesthetic. Cotton/modal blend for a softer, more premium hand. Modal for luxury drape and softness. Specify minimum 200 GSM for any bodysuit marketed for second-skin or fitted wear -- lighter fabrics may be insufficiently opaque.

V-neck and scoop neck are the highest-volume commercial performers -- universal, layering-friendly, flattering across body types. Square neck is the strongest current fashion direction. Long-sleeve versions in rib perform strongly in autumn/winter. The polo collar bodysuit (using polo construction from Family 03) is an emerging premium-casual option.

Same factory, same machines, same fabric system. Two additional operations: (1) the crotch extension panels cut and sewn onto the body hem, and (2) the snap application and gusset lining construction. These two operations add $2.50-4.00 CMT. The bodysuit is in the same production run as the T-shirt range -- no factory change required.

GOTS x1.23 for organic cotton jersey. OEKO-TEX STANDARD 100 as baseline. RCS for recycled cotton. For modal: TENCEL or equivalent Lenzing certification if using Lenzing fibres. Certifications for the gusset lining fabric must match the outer -- the gusset is in direct intimate contact.

Same regions as T-shirt (Family 01): China primary affordable, Portugal Made in Europe, Turkey EU delivery, Vietnam growing premium, India GOTS cotton. No specialist factory required beyond standard jersey knit capability with snap application experience.

Yes -- using the same cup construction as the sports bra (Family 08). Removable soft pad in a chest pocket is the most common approach. Sewn-in foam cup for shape. Specify cup pocket width and depth on the tech pack. A bodysuit with cups eliminates the need to wear a bra underneath -- a strong commercial benefit for fitted styles.

HS 6109 -- jerseys, pullovers, T-shirts, and similar articles of knitted or crocheted fabric. The bodysuit is classified with jersey tops despite having a crotch construction, because it is worn as a top garment. Confirm with your customs broker for your specific markets.