Over 90% of the activewear on the market is built on polyester — a petroleum-based plastic. And while the industry has spent decades marketing polyester as a “performance fabric,” the science tells a different story. Polyester sheds microplastics with every wash and wear cycle. It traps heat and breeds odor-causing bacteria. And research increasingly links synthetic textile chemicals — BPA, PFAS, phthalates — to endocrine disruption, skin irritation, and reproductive harm.

We’re not the only brand that recognized this problem. A growing number of companies are engineering activewear from natural and plant-based fibers — proving that high performance and clean materials aren’t mutually exclusive. As a brand that has committed to zero polyester and zero polyamide across our entire line — and uses only biodegradable CiCLO® nylon where compression demands it — we have a deep understanding of what it takes to make non-toxic activewear that actually performs.

This guide is our honest assessment of the brands doing it right. We’ve evaluated each one on the criteria that matter most: fabric composition, chemical safety, third-party certifications, performance characteristics, and environmental impact. We’ve included ourselves in this comparison because we believe transparency builds trust — and because we think the data speaks for itself.

What Makes Activewear “Plastic-Free”?

Before evaluating any brand, it’s important to define what “plastic-free” actually means in this context — because the term is used loosely across the industry.

True plastic-free activewear contains no polyester, no nylon (polyamide), and no conventional petroleum-based fibers in its primary fabric. Most brands in this space use one of three base fibers: TENCEL™ Lyocell (from eucalyptus), TENCEL™ Modal (from beechwood), organic cotton, or merino wool. Some also use hemp or bamboo-derived fibers.

The stretch component is where it gets complicated. Nearly all activewear requires some elastane (spandex) for mobility and fit — and elastane is technically synthetic. The question is how much, what kind, and whether it’s been tested for harmful substances. Some brands use conventional elastane at 5–8%. Others use certified alternatives like ROICA® V550 (biodegradable, Cradle-to-Cradle Gold certified) or bio-based elastane derived from renewable sources. The difference matters — both for your skin and for the garment’s end-of-life biodegradability.

When evaluating brands below, we focused on these specific criteria:

• Primary fiber source — What is the garment mostly made of? Higher percentages of natural or plant-based fiber generally mean better breathability, moisture management, and skin safety.
• Stretch component — What type of elastane is used, and at what percentage? Is it conventional, recycled, or biodegradable?
• Chemical safety — Has the product been tested for BPA, PFAS, phthalates, formaldehyde, and other endocrine-disrupting compounds? Which third-party certifications verify those claims?
• Performance characteristics — How does the fabric handle moisture, odor, temperature regulation, stretch recovery, and durability under real training conditions?
• Sustainability — Is the production process closed-loop? Are the fibers biodegradable? What’s the environmental footprint of the raw material sourcing?

The Brands

EveryRep

Headquarters: Ohio, USA
Primary Fabric: TENCEL™ Modal Active (beechwood-derived)
Composition: 85–95% TENCEL™ Modal Active / 5–15% bio-based elastane
Certifications: OEKO-TEX® Standard 100
Chemical Safety: BPA-free, PFAS-free, phthalate-free (BodySafe Guarantee)
Product Range: Men’s and women’s full line — T-shirts, tank tops, sports bras, leggings, shorts, joggers, hoodies, jackets, underwear

We use TENCEL™ Modal Active exclusively across our entire product line — a fiber derived from sustainably harvested beechwood processed through Lenzing’s closed-loop system, which recovers over 95% of solvents. What distinguishes our approach is the zero-exception policy on conventional synthetics: every garment we produce contains zero polyester and zero polyamide, with only biodegradable CiCLO® nylon used where compression performance demands it.

Our elastane is bio-based rather than petroleum-derived, keeping the entire composition as far from plastics as current textile science allows. The BodySafe Guarantee means every product is independently verified free from BPA, PFAS, and other endocrine-disrupting compounds.

On the performance side, TENCEL™ Modal’s moisture management operates through hydrophilic fiber absorption — the fiber itself draws moisture in and releases it through evaporation, rather than relying on chemical surface finishes that degrade after repeated washing. This is a fundamentally different mechanism than what polyester uses, and it’s why the wicking performance doesn’t diminish over the garment’s lifespan.

We also produce compression-grade leggings and compression shorts using our BioLuxe® fabric — a premium nylon treated with CiCLO® biodegradable technology, delivering the compression and stretch recovery these products demand while maintaining a commitment to non-toxic, reduced-plastic construction.

Best for: Athletes and active individuals who want a full wardrobe solution — from training to everyday wear — with zero polyester across every product category, backed by a formal chemical safety guarantee.

Reprise Activewear

Headquarters: USA
Primary Fabric: TENCEL™ Lyocell (eucalyptus-derived)
Composition: 93% TENCEL™ Lyocell / 7% spandex
Certifications: OEKO-TEX® Standard 100 (on TENCEL™ fiber; spandex component not yet certified)
Chemical Safety: PFAS-free by material choice; no formal BPA testing disclosed
Product Range: Primarily women’s — leggings, sports bras, tanks, bike shorts, joggers

Reprise was one of the first brands to build an entire activewear line around TENCEL™ Lyocell, launching via Kickstarter in 2018 with a clear mission of removing plastics from clothing. Their 93/7 TENCEL-to-spandex ratio is among the highest in the market, and the resulting fabric is exceptionally soft with good stretch recovery.

Their manufacturing is based in Portugal, which places production under EU environmental and labor standards. The brand has been transparent about the fact that their 7% spandex component is not yet OEKO-TEX certified, and they’ve stated publicly that sourcing plant-based spandex is an active goal.

One distinction worth noting: Reprise uses TENCEL™ Lyocell (eucalyptus-based) rather than TENCEL™ Modal (beechwood-based). Lyocell and Modal are both Lenzing cellulosic fibers, but they differ in hand feel and performance characteristics. Lyocell tends to be slightly more structured and cooling. Modal tends to be softer with better drape and color retention. Neither is objectively superior — the choice depends on the intended application and feel.

Best for: Women seeking ultra-soft, minimalist TENCEL Lyocell activewear with a high natural-fiber ratio from a women-owned independent brand.

Tripulse

Headquarters: Sweden (manufacturing in Portugal)
Primary Fabric: TENCEL™ Lyocell
Composition: 84–100% TENCEL™ Lyocell / 0–16% ROICA® V550 or EF385
Certifications: OEKO-TEX® Standard 100 (Class 1 / baby-safe), EU Ecolabel, FSC®, PEFC™, REACH, bluesign®, Climate Neutral
Chemical Safety: Certified free from harmful chemicals across the entire garment
Product Range: Primarily women’s line; limited men’s line

Tripulse stands out for having the most comprehensive certification stack in this space. Their OEKO-TEX certification is Class 1 — the highest tier, rated safe for infant skin contact. They also hold EU Ecolabel, REACH compliance, and bluesign® certification, which collectively cover chemical safety across the entire garment supply chain, not just the primary fiber.

Their approach to the elastane question is particularly thoughtful. Rather than conventional spandex, they use ROICA® V550 (biodegradable, Cradle-to-Cradle Gold) or ROICA® EF385 (recycled from pre-consumer materials). Their waistbands use organic cotton blended with natural rubber instead of elastic. Even their care labels are made from TENCEL or organic cotton with water-based ink.

Best for: Consumers who prioritize third-party certification depth and want the most independently verified chemical safety profile available in plastic-free activewear.

MATE the Label

Headquarters: Los Angeles, USA
Primary Fabric: GOTS-certified organic cotton
Composition: 92% organic cotton / 8% spandex
Certifications: GOTS, Climate Neutral, B Corp, 1% for the Planet
Chemical Safety: Adheres to strict restricted substance list; non-toxic dyes; no PFAS, BPA, or formaldehyde
Product Range: Women’s and men’s activewear plus basics

MATE takes a different material path than the TENCEL-based brands — building their MOVE activewear collection on organic cotton. The advantage of this approach is familiarity (cotton feels like cotton) and a very low chemical risk profile, since GOTS certification is one of the most stringent organic textile standards in the world.

The tradeoff is performance. Cotton — even organic cotton — absorbs and retains moisture rather than wicking it away. For high-intensity training, running, or hot-weather workouts, cotton’s moisture retention can become a comfort and thermoregulation issue.

Best for: Consumers who prefer organic cotton over semi-synthetic cellulosic fibers, prioritize GOTS certification, and primarily do low-to-moderate intensity training or want clean athleisure basics.

Ryker Clothing Co.

Headquarters: USA
Primary Fabric: 100% organic cotton and 100% merino wool (separate lines)
Composition: 100% single-fiber construction (no blended elastane)
Certifications: GOTS-certified organic cotton, OEKO-TEX® Standard 100; independent third-party BPA/PFAS testing
Chemical Safety: Independently lab-tested BPA-free, PFAS-free, hormone disruptor-free
Product Range: Men’s — shorts, underwear (no women’s line currently)

Ryker takes the most uncompromising position on synthetic content: their garments contain zero elastane. They achieve fit and stretch through fabric construction (knit pattern and weight) rather than blended stretch fibers. The result is a product that is 100% natural fiber by composition — which is exceptionally rare in activewear.

What sets Ryker apart is their commitment to independent lab testing. Rather than relying solely on fiber-level certifications, they test finished products for BPA, PFAS, and hormone disruptors — a more rigorous approach that accounts for chemicals that can be introduced during dyeing, finishing, or assembly.

Best for: Men who want the absolute purest natural-fiber activewear with independently verified chemical safety testing, and who don’t need high compression or stretch.

Paka

Headquarters: USA (sourcing from Peru)
Primary Fabric: Alpaca wool and TENCEL blends
Composition: Varies by product — alpaca wool primary
Certifications: Certified B Corp
Chemical Safety: Natural fiber positioning
Product Range: Men’s and women’s tanks, T-shirts, joggers, lightweight layers

Paka’s differentiator is alpaca wool — a fiber with natural thermoregulation, moisture-wicking, and antimicrobial properties. Alpaca wool performs exceptionally well for temperature regulation — keeping you warm in cold conditions and breathing well in moderate heat. It’s also naturally hypoallergenic and softer than sheep’s wool.

Best for: Outdoor athletes and cold-weather trainers who want natural thermoregulation from animal fiber, with strong ethical sourcing values.

Boldwill (formerly Iron Roots)

Headquarters: Netherlands
Primary Fabric: Natural-origin materials (eucalyptus, organic cotton, wood-based fibers)
Composition: Primarily cellulosic and organic cotton blends
Product Range: Men’s and women’s T-shirts, tanks, shorts, joggers

Boldwill is a European brand focused on replacing synthetic sportswear with natural alternatives. Their positioning around “Natural Progression” acknowledges that achieving 100% plastic-free performance wear is an evolving process, and they’re transparent about their journey.

Best for: European-based consumers looking for a natural-origin activewear brand with an honest, iterative approach to removing synthetics from sportswear.

Head-to-Head Comparison

How to Choose the Right Brand for You

The “best” plastic-free activewear brand depends on how you train, what you value most, and what products you need.

• If you train at high intensity and want a full wardrobe solution — EveryRep offers the broadest product range with consistent TENCEL™ Modal construction.
• If certification depth is your top priority — Tripulse’s OEKO-TEX Class 1 (baby-safe) certification is the most comprehensive in this space.
• If you prefer organic cotton — MATE the Label’s GOTS-certified organic cotton provides a familiar feel with strong ethical credentials.
• If you want zero elastane — Ryker’s 100% natural fiber shorts deliver the absolute purest construction.
• If you train outdoors — Paka’s alpaca wool offers natural thermoregulation that cellulosic fibers can’t match.

Why This Matters More Than You Think

The activewear you choose isn’t just a style decision — it’s a health decision. Research continues to demonstrate that chemicals found in synthetic textiles can migrate through the skin during exercise, when pores are dilated and sweat acts as a transport medium. BPA has been found in major-brand sports bras and leggings at levels up to 40 times the safe exposure limit under California law. PFAS “forever chemicals” have been detected in products from some of the industry’s largest names.

Every brand listed in this guide has made a conscious decision to move away from that model. We believe the activewear industry is at an inflection point. Consumer awareness of textile toxicity is growing rapidly, and the brands investing in genuinely clean materials now will define the next era of performance wear.