Are Activewear Fabrics Safe? PFAS, BPA and Polyester Leggings Explained

Quick answer: Activewear is not automatically unsafe. But many leggings, sports bras, gym tops and “performance” fabrics are made from plastic-based fibres such as polyester, nylon and elastane, and may also use dyes, coatings, finishes, prints or treatments that consumers are rarely told about. Recent investigations, testing and greenwashing claims have raised legitimate questions about what is really in the clothes marketed as “wellness”, “performance” and “sustainable”.

For years, sportswear brands have sold us the same promise: buy more technical clothing and you will feel healthier, stronger, fresher and more prepared.

Quick-dry. Sweat-wicking. Odour-control. Anti-chafe. Stain-resistant. Cooling. Recycled bottles. Planet-friendly performance.

But those claims can hide a more complicated story.

Modern activewear is often made from fossil-fuel-derived plastic fibres, blended with stretch materials that are difficult to recycle, dyed with complex chemical systems and sometimes finished with coatings designed to repel water, resist stains, reduce odour or alter how the fabric behaves against the skin.

The question is not whether every pair of leggings is “toxic”. The question is why consumers are expected to spend premium prices on “wellness” clothing without being told exactly what materials, coatings and chemical treatments make it perform.

Are activewear fabrics safe?

There is no single answer because “activewear” covers a huge range of products and materials.

A plain cotton T-shirt is very different from a compression legging made from polyester and elastane, printed with rubberised branding, treated for odour control and marketed as wrinkle-resistant, water-repellent or stain-resistant.

Some performance qualities come from the structure of the fabric itself. Polyester and nylon absorb less water than cotton, so they can feel quicker to dry. Moisture-wicking can be created through yarn shape and knit construction.

But other claims can depend on additional finishes, coatings or treatments.

That is why consumers should stop asking only, “What percentage polyester is this?” and start asking, “What has been added to this fabric to make it behave differently?”

What is the Lululemon PFAS investigation about?

In April 2026, the Texas Attorney General announced an investigation into whether Lululemon may have misled consumers about the safety, quality and health impacts of its products, including whether certain activewear may contain PFAS.

PFAS are often called “forever chemicals” because many are highly persistent in the environment. They have been used in consumer products for water-, stain-, oil- and grease-resistant properties.

The investigation is not a finding that Lululemon has broken the law. It is an active inquiry into whether the brand’s products, supply-chain practices, restricted-substances policies and marketing claims match what consumers are being sold.

Lululemon has said it does not currently use intentionally added PFAS in its products and that it phased out PFAS in fiscal year 2023, after having used them in a limited number of durable water-repellent items.

The important point is bigger than one brand. If an activewear company markets itself around wellbeing, mindful movement and sustainability, consumers are entitled to ask whether its materials and finishes reflect those values.

BPA in sports bras and athletic shirts: what testing found

PFAS are not the only chemical group raising questions in activewear.

In 2022 and 2023, the US nonprofit Center for Environmental Health issued California Proposition 65 notices and brought enforcement actions involving BPA in sports bras, athletic shirts and other activewear products sold by several major brands.

The group said its testing found that some products could expose wearers to BPA above California’s Proposition 65 safe-harbour level. Brands named in notices or related actions included Athleta, Nike, The North Face, Brooks, Asics, FILA, Reebok, New Balance, Mizuno and others.

BPA is a bisphenol. It is widely known because of concern around plastic food containers, but bisphenols can also be relevant to textile and polymer manufacturing systems.

These notices do not prove that every sports bra or athletic top from those brands is unsafe, and they do not establish that all activewear contains BPA. But they are a serious reminder that clothing is not chemically neutral simply because it is soft, stretchy or marketed for fitness.

What “performance fabric” can really mean

Performance language has become so normal that many shoppers no longer question it.

But each claim can point to a different material or treatment pathway.

Marketing claim	What it can involve	What to ask
Sweat-wicking / quick-dry	Polyester or nylon fibre structure, knit construction, hydrophilic treatments	Is the function created by the fibre design alone, or has an added finish been used?
Water-repellent / stain-resistant / easy-clean	Possible fluorinated or PFAS-related chemistry, coatings or durable water-repellent finishes	Is the garment PFAS-free? Has it been independently tested?
Wrinkle-free / crease-resistant / permanent-press	Resin finishes, including formaldehyde-based systems in some textile applications	Does the product use formaldehyde-free finishing chemistry?
Odour-control / antibacterial / antimicrobial	Silver, zinc compounds, biocides or other antimicrobial treatments	What treatment is used, and is it really needed for everyday exercise clothing?
Compression / sculpting / second-skin	High elastane content, nylon, polyester blends and tight garment construction	What is the exact fibre mix, and is there a lower-synthetic version?
Recycled-bottle fabric	Usually recycled PET polyester, often blended with elastane or other fibres	How much is recycled content, what is the blend, and can the garment be recycled at end of life?

 

A big problem with these brands is lack of transparency and education. Consumers are rarely told which technical features come from fabric engineering and which depend on added chemical complexity.

Is recycled plastic activewear actually sustainable?

“Made from recycled plastic bottles” has become one of fashion’s most powerful sustainability claims.

There is a real benefit to using recycled PET in place of virgin PET: it can reduce demand for newly produced fossil-fuel-derived plastic.

But that is not the end of the story.

When a recyclable bottle is turned into a polyester garment, it often becomes part of a blended textile with elastane, dyes, prints, finishes and trims. That garment can be difficult or impossible to recycle back into a similar product at the end of its life.

It is also still plastic.

• Recycled polyester sheds synthetic microfibres during washing and wear.

• It can still require dyes, finishes and chemical processing.

• It is often blended with elastane, which makes textile-to-textile recycling harder.

• It can turn a bottle that might have been recycled again into a garment with a less certain end-of-life route.

Recycled plastic is not meaningless. But it is not a free pass for overproduction, hidden chemistry or disposable fashion.

Which chemicals and materials should you ask about in activewear?

Not every garment contains every substance below. But these are the material groups most worth asking brands about.

PFAS

PFAS may be relevant to water-repellent, stain-resistant, grease-resistant and some easy-clean treatments. Certain PFAS are associated in human and toxicology research with immune, developmental, reproductive, thyroid and other health concerns.

Look for clear “PFAS-free” commitments backed by product-level information, not only broad corporate statements.

Bisphenols, including BPA

BPA is a well-known endocrine-active chemical. Testing and legal notices involving sports bras and athletic tops have raised questions about potential exposure through some textile products.

Consumers should not assume “BPA-free” unless a brand provides a clear statement or independent certification.

Phthalates and PVC

Phthalates are most relevant to PVC prints, shiny graphics, rubberised logos, coated details and flexible plastic components. Several phthalates are restricted because of reproductive and developmental concerns.

Plain fabric is not the same as a heavily branded garment with plasticised graphics and coated panels.

Formaldehyde-based wrinkle-resistant finishes

Wrinkle-resistant and permanent-press finishes can involve formaldehyde-based resins. These are known to cause allergic contact dermatitis in some people, especially when clothing is worn close to warm skin for long periods.

Antimicrobial and odour-control treatments

Odour-control products may use silver compounds, zinc compounds, biocides or other antimicrobial systems. These treatments are often presented as a convenience feature, but they should not be assumed necessary for ordinary gym clothing.

Polyester, nylon and elastane

These are fossil-fuel-derived synthetic fibres. They are not automatically dangerous, but they are plastic-based, can shed microfibres and can be combined with a range of dyes, coatings, finishes and additives.

Why heat, sweat and long wear matter

Workout clothes are not worn in neutral conditions.

They are worn against warm skin, often tightly fitted, while sweating, stretching, running, cycling, lifting or practising yoga. Many people then stay in them for hours after a workout.

That does not automatically prove that chemicals from a garment are absorbed at a harmful dose. But it does make the question more relevant than it would be for a loose jacket worn briefly outdoors.

Long wear, close skin contact, heat and sweat are precisely why activewear should not be treated as an ordinary fashion category.

Consumers deserve more than vague reassurance. They deserve clear disclosure of fibre content, finishes, treatments and restricted-substance policies.

Why “eco activewear” claims are facing backlash

Sportswear brands have leaned heavily into words such as sustainable, conscious, recycled, circular, planet-friendly and lower-impact.

But broad environmental claims are increasingly being challenged by regulators, campaigners and consumers who want to know what those words actually mean.

Lululemon faced a US consumer greenwashing lawsuit over its “Be Planet” campaign. The case was dismissed in 2025, which means the court did not allow that particular claim to proceed. It does not mean every sustainability statement made by every sportswear company has been independently validated.

More broadly, regulators are becoming less tolerant of vague environmental marketing that does not explain the limits of a claim.

“Made from recycled bottles” may be true. It can still leave out the fossil-fuel-based fibre, the blended construction, the microfibre shedding, the chemical finishes and the garment’s uncertain end of life.

How to choose lower-chemical activewear without replacing everything

You do not need to throw out your workout wardrobe. The most useful changes are practical and gradual.

• Choose simpler garments for lower-intensity exercise, such as organic cotton T-shirts, cotton-rich joggers or natural-fibre layers where suitable.

• Reserve highly technical garments for activities where their function is genuinely needed.

• Be cautious of unnecessary “stain-resistant”, “water-repellent”, “anti-odour” and “easy-clean” claims.

• Look for product-level PFAS-free, formaldehyde-free or restricted-substances information.

• Choose plain styles over heavily printed, rubberised or coated versions where possible.

• Buy fewer, better-fitting garments that you will wear for years.

• Wash activewear after use with a fragrance-free detergent and avoid fabric conditioner, which can coat fibres and reduce breathability.

• Air dry where practical to extend garment life and reduce heat damage.

What activewear brands should disclose

Consumers should not need a chemistry degree to buy a pair of leggings.

Brands should clearly disclose:

• Exact fibre composition, including elastane percentage.

• Whether PFAS are intentionally added or detected in the final product.

• Whether garments use water-repellent, stain-resistant, antimicrobial, anti-odour or wrinkle-resistant finishes.

• Whether PVC, phthalates, formaldehyde-based resins or fluorinated coatings are used.

• What “recycled content” means in percentage terms.

• Whether the garment can actually be recycled at the end of its life.

• Which restricted-substance list applies and how final products are tested.

Wellness marketing should not be a substitute for ingredient disclosure.

A simpler wash for activewear

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Frequently asked questions

Are polyester leggings safe to wear?

Polyester leggings are not automatically unsafe. But polyester is a plastic-based fibre, and the finished garment may also include dyes, elastane, prints, coatings or treatments. The most useful question is what else has been added to the fabric.

Do activewear clothes contain PFAS?

Some can, particularly products marketed as water-repellent, stain-resistant, grease-resistant or easy-clean. Not every activewear garment contains PFAS, so look for product-level PFAS-free confirmation where possible.

Can sports bras contain BPA?

Testing and California Proposition 65 notices have raised concerns about BPA in some sports bras and athletic shirts. This does not mean every sports bra contains BPA, but it is a reason to expect clearer material disclosure from brands.

Is recycled polyester better than virgin polyester?

Recycled polyester can reduce demand for virgin PET. However, it remains plastic-based, can shed microfibres and is often difficult to recycle again when blended with elastane, dyes and finishes.

Does sweat increase chemical exposure from workout clothes?

Heat, sweat and close skin contact make activewear a relevant category for exposure research. The exact amount of chemical transfer depends on the substance, garment and conditions, and is not known for every product.

Should I stop wearing synthetic activewear?

No. The realistic goal is to reduce unnecessary exposure and unnecessary consumption. Choose simpler fabrics where practical, reserve technical products for genuine need and ask brands for better disclosure.

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Glossary

Activewear: Clothing designed for exercise, sport or movement, often using synthetic fibres and stretch fabrics.

PFAS: A large group of synthetic chemicals used in some products for water, grease and stain resistance.

BPA: Bisphenol A, a chemical used in some plastic and resin systems that is widely studied for endocrine activity.

Endocrine disruptor: A chemical that can interfere with hormone signalling in the body.

Polyester: A synthetic fibre commonly made from PET plastic.

Elastane: A synthetic stretch fibre, also known as spandex or Lycra.

Microfibres: Tiny fibres released from textiles during wear and washing. Synthetic microfibres are a type of microplastic pollution.

Restricted Substances List: A company policy setting limits or bans on certain chemicals in products and manufacturing.

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Keep reading

• What Are Forever Chemicals? Hidden PFAS in Everyday Products

• Synthetic School Sportswear: PFAS, Plastic Fabrics and Safer Uniform Choices

• Microplastics in Bottled Water: Glass vs Plastic

• How to Reduce Microplastics in Food

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Research and further reading

• Texas Attorney General: Investigation into Lululemon over potential PFAS in activewear

• Center for Environmental Health: BPA testing in sports bras and athletic shirts

• European Commission: PFAS and stain- and water-resistant textile coatings

• EU textile criteria: PFAS, phthalates and antimicrobial treatments

• ATSDR: PFAS health effects