How We Helped an U.S. Athleisure Brand Reduce Pilling-Related Complaints by 35% Through Fabric Engineering and Durability Testing

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Issue Time: 2026/1/23 11:21:24

Summary

An established U.S. athleisure brand faced rising pilling complaints on its core leggings. Bloomto optimized the fabric for soft feel + higher abrasion resistance, aligned wear-relevant pilling tests, and added bulk QC checkpoints from fabric intake to final inspection. Result: 35% fewer pilling-related complaints and smoother reorders.

Client Background

An established U.S. athleisure brand was scaling its "everyday leggings"and lounge-to-training sets—products designed for frequent wear, long wash cycles, and high customer review visibility.

Because the brand's core styles were reorder-driven, long-term durability mattered as much as fit and feel. The brand partnered with Bloomto to improve fabric durability without sacrificing the soft handfeel customers loved.

Client Challenges

1) Pilling complaints were increasing after real-world wear

Customer feedback started to cluster around friction zones:

• inner thighs

• seat area

• waistband edges

Even when leggings looked great out of the package, pilling after a few weeks created negative reviews, returns, and reduced repeat purchase intent.

2) Softer handfeel was trading off with durability

The brand wanted a "buttery"touch, but their previous fabric route created a durability gap. Attempts to fix pilling often made the fabric feel stiffer, shinier, or less premium—hurting the brand's signature experience.

3) Lack of a consistent durability standard for bulk reorders

Past suppliers relied on subjective judgment ("this is fine"), while the brand needed a repeatable system:

• defined abrasion/pilling test methods

• pass/fail thresholds linked to approved samples

• bulk inspection checkpoints to prevent drift across dye lots and reorders

Bloomto Solution (What We Did)

1) Fabric engineering focused on "soft + durable"

Bloomto adjusted the fabric route to improve abrasion resistance while keeping a premium handfeel:

• optimized yarn and knit structure for higher durability in friction zones

• balanced stretch recovery to reduce surface stress during movement

• aligned finishing parameters to maintain softness without increasing shine

2) Wear-relevant pilling & abrasion testing

We aligned testing to real-use conditions and created a clear standard:

• pilling evaluation under controlled friction cycles

• abrasion checks to simulate long-term wear

• baseline comparison against the approved sample as the quality reference

3) Bulk-ready QC checkpoints to protect durability outcomes

We implemented durability-focused controls across production:

• incoming fabric checks (handfeel consistency, weight, stretch recovery)

• inline monitoring for sewing and high-friction construction points

• final inspection with durability-related criteria tied to the standard

This prevented "good sample, weak bulk" outcomes and made reorders repeatable.

Results & Impact

After rollout across the brand's core leggings program:

• Pilling-related complaints decreased by 35%

• Improved review sentiment and reduced return pressure

• More consistent handfeel across dye lots, supporting reorder confidence

• Fewer development cycles needed for reorders thanks to clear durability standards

Client Feedback

"Bloomto helped us solve pilling without losing the soft feel our customers expect. The testing standards were clear, bulk consistency improved, and we saw a noticeable drop in durability complaints."

Conclusion

By combining fabric engineering, wear-relevant durability testing, and bulk QC checkpoints, Bloomto helped the brand improve long-term leggings durability without sacrificing the signature soft handfeel. The program reduced pilling-related complaints, improved bulk consistency across reorders, and made future scale-ups easier to repeat with clear standards.

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