Beyond the Hoodie: How to Expand Your Streetwear Line into Custom Varsity Jackets and Tracksuits

For many emerging streetwear founders, the hoodie is the "entry drug." It is the staple of every collection and the most reliable seller. However, as the market becomes increasingly saturated, the most successful brands in 2025 and 2026 are those that evolve into full lifestyle labels.

If your brand has mastered the oversized hoodie or the heavyweight 400GSM+ pullover, the logical next step is to diversify. Expanding into custom varsity jackets and tracksuits not only increases your Average Order Value (AOV) but also solidifies your status as a serious contender in the fashion industry.

Why Diversification is the Key to Streetwear Longevity

Relying solely on one product category is a risk. By introducing outerwear and coordinated sets, you tap into different consumer needs:

Higher Price Points:

A premium varsity jacket can command 2–3x the retail price of a hoodie.

The "Set" Trend:

Consumers are increasingly looking for full "fits." Selling a matching tracksuit is an easy way to double your revenue per customer.

Brand Authority:

Producing complex garments like jackets proves your brand’s commitment to quality and technical design.

1. The Varsity Jacket: The Ultimate Streetwear Statement Piece

The varsity (or letterman) jacket has transitioned from high school nostalgia to a high-fashion staple. For a brand owner, it is the perfect canvas for storytelling.

Choosing Your Materials: Wool, Leather, and Satin

When moving from fleece to jackets, you must understand your materials. High-end brands often use Melton Wool for the body to provide structure. When it comes to sleeves, you must decide between genuine cowhide or high-quality vegan leather. If you are looking for a more retro, lightweight aesthetic, satin varsity jackets offer a unique sheen that stands out in a crowd of matte cotton.

Advanced Branding Techniques

Unlike hoodies, varsity jackets allow for heavy-duty decoration. Consider chenille patches for that 3D retro look, or intricate embroidery across the back panel. Deciding between screen printing vs embroidery is crucial here, as jackets almost always demand the premium feel of needlework or leather applique.

2. Mastering the Tracksuit: The Uniform of Modern Streetwear

The tracksuit is no longer just for the gym; it’s the modern suit. To get this right, you need to focus on the "Total Look."

Matching Fabrics and Color Batches

One of the biggest mistakes in B2B manufacturing is a slight color mismatch between the top and the joggers. When expanding into tracksuits, ensure your manufacturer uses the same dye lot, referencing specific Pantone Fashion & Home codes, to maintain 100% color consistency. Whether you choose French Terry vs Fleece, consistency is what makes a tracksuit look expensive.

Fit Mentality: Slim vs. Baggy

Streetwear sweatsuits currently lean toward a heavyweight fleece with an oversized, "stacked" fit at the ankles. This requires precise seam engineering like Flatlock or Chain stitching to ensure the heavy fabric hangs correctly without bursting at the stress points during movement.

3. Transitioning Your Supply Chain: What to Ask Your Manufacturer

Expanding your line requires more technical expertise from your factory. If you’ve been working with a basic "hoodie shop," you may need to verify their capabilities for private label manufacturing.

Technical Construction Requirements

Hardware Sourcing:

Can they provide high-quality YKK zippers or custom-branded snap buttons?

Finishing Touches:

Don't forget that custom hang tags and neck labels are the final 10% of premium branding that justifies a higher price point for jackets.

Wash Effects:

If you want that vintage look, ask if they can apply pigment or acid washes to your tracksuits.

FAQ: Expanding Your Streetwear Collection

What is the typical MOQ for varsity jackets compared to hoodies?

Usually, varsity jackets have a higher cost per unit due to the complexity of the materials. However, many custom hoodie manufacturers can offer lower MOQs if you are already a high-volume client for other items.

Can I use the same fabric for my hoodies and my tracksuits?

Absolutely. In fact, we recommend it. Using the same Cotton Fleece fabric ensures your sets match perfectly and simplifies your sourcing.

Is Cut & Sew better than ready-made for jackets?

For varsity jackets, Cut & Sew is almost always better, as it allows you to customize the lining, ribbing, and sleeve materials which are impossible to change on blanks.

Final Thoughts: Building a Cohesive Collection

Expanding "Beyond the Hoodie" is about creating a visual universe. When you pair a premium top with a matching bottom and a structured jacket, you're selling a complete aesthetic.

Ready to scale?

At Brand Stuff, we help you move from a single product to a full-scale streetwear collection.

Get a Quote for Your Custom Varsity Jackets & Tracksuits Today