2026 State of Gym Apparel Report

This is the first industry report of its kind. Based on data from over 30,000 completed custom apparel orders for 5,000+ gym owners across all 50 states since 2008, this report captures what is actually happening in gym apparel: what sells, what does not, and where the opportunity is for gym owners who treat merch as a real revenue stream.

Key Findings

1. The average gym apparel drop generates $800-$1,500 in gross profit.

This figure accounts for all gym sizes. Smaller gyms pull the average down, larger gyms pull it up. But even the median gym generates meaningful revenue per drop when running a preorder system.

2. Gyms running 4-6 drops per year earn 3-4x more than gyms running 1-2.

Revenue does not scale linearly with drops. There is a multiplier effect: consistent drops train members to expect and anticipate apparel releases, which increases participation per drop over time.

3. Preorder conversion rates average 20-35% of active members.

This is the critical benchmark. If your preorder converts less than 15% of your active member base, your promotion strategy needs work. Above 30% indicates a strong community and excellent execution.

4. Hoodies and premium items drive the highest profit per drop.

Drops that include a premium item like a hoodie, quarter-zip, or embroidered hat generate 40-60% more profit than tee-only drops. The margin per unit is higher, and members buy both the tee and the premium item.

5. Women-specific cuts increase total order volume by 15-25%.

Drops that include at least one women-specific option, such as a crop tee or relaxed fit, consistently sell more total units than unisex-only drops. The days of one-style-fits-all are over.

6. Fall drops have the highest average order value.

September and October drops generate the highest per-order spend because hoodies, long sleeves, and outerwear carry premium pricing. Gyms that skip fall drops miss their highest-margin window.

7. Marketing effort is the number one predictor of drop success.

We have tracked this across thousands of orders. Gyms that use 5+ marketing touchpoints per drop, such as class announcements, social media posts, emails, samples, and countdowns, consistently outperform gyms that rely on a single post by 2-3x.

8. The most common mistake is pricing too low.

The average gym sells tees for $22-25 but could comfortably price at $28-32 given the design quality and community value. Every $3 increase across a 40-unit order adds $120 in pure profit.

Trends Over Time

Since 2008, we have observed several shifts. Order frequency has increased as the preorder model has replaced bulk purchasing. Average design complexity has grown as gyms have moved beyond simple logo tees. Premium product categories like embroidered items and performance fabrics have grown from a small percentage of orders to a significant share. And the diversity of garment options per drop has expanded, with multi-product drops becoming the standard for high-performing gyms.

What This Means for Gym Owners

The opportunity in gym apparel is not shrinking. It is growing, but only for gym owners who treat it as a system rather than an afterthought. The data consistently shows that the gap between high-performing and low-performing apparel programs comes down to execution: pricing, promotion, frequency, and product mix.

If you are underperforming in any of those areas, the fix is straightforward and the upside is meaningful.

Methodology

This report draws on operational data from Forever Fierce's completed orders from 2008 to 2025. All revenue and margin figures are based on real client transactions. Member conversion rates are calculated from reported gym membership sizes and order volumes. No survey data or estimates were used.