Global Thermal Underware Market Growth, Share, Size, Trends and Forecast (2025 - 2031)

• In November 2022, PH Corp. renewed licences with G-IlI Apparel Group, Ltd. as part of a multi-year shift to bring core product categories in-house.

• In January 2023, Acai Outdoorwear, a female-first outdoor clothing manufacturer, has secured a GBP3m (USD 3.66m) investment from Growth Partner, which will allow the company to expand internationally and outside the direct-to-consumer channel.

The global thermal underwear market can be segmented by material, application, distribution channel, and region, each contributing to the diverse growth dynamics of the industry. By material, the market is primarily divided into natural fibers, such as cotton and wool, and synthetic fibers, including polyester, nylon, and blends. Natural fibers, especially merino wool, are known for their superior insulation and moisture-wicking properties, making them highly desirable for consumers seeking high-performance thermal wear. Wool, in particular, remains popular for its breathability, softness, and warmth. On the other hand, synthetic fibers offer affordability, durability, and quick-drying capabilities, appealing to budget-conscious consumers and athletes. The increasing use of blended fabrics combining both natural and synthetic fibers is also gaining traction as these products provide a balance of comfort, functionality, and affordability.

In terms of application, the thermal underwear market can be categorized into men’s, women’s, and children’s wear. The men’s segment holds a significant share of the market due to the high demand for thermal garments that offer warmth and comfort during outdoor and athletic activities, especially in colder regions. Women’s thermal underwear is also a rapidly growing segment, driven by rising fashion trends and the growing popularity of form-fitting, stylish thermal wear that blends functionality with design. Additionally, the children's segment is expanding as parents seek high-quality, comfortable thermal wear for their children to ensure warmth during winter seasons. Across all segments, the use of thermal underwear in outdoor sports and recreational activities, such as skiing, hiking, and camping, is driving demand, with more consumers recognizing the benefits of thermal wear for both everyday use and specialized needs.

The distribution channels for thermal underwear are split between offline and online retail. Offline retail, including department stores, specialty apparel stores, and sportswear outlets, continues to play a vital role in this market, as consumers prefer to physically evaluate products for comfort, fit, and quality. However, online retail has been growing rapidly, fueled by the increasing popularity of e-commerce platforms, where consumers can easily compare prices, read reviews, and access a wide range of thermal underwear options. The convenience of online shopping, coupled with attractive discounts and fast delivery options, has driven more consumers to purchase thermal wear through digital channels. Additionally, direct-to-consumer (DTC) sales through brand websites are gaining momentum, enabling manufacturers to engage with customers directly and offer personalized shopping experiences. As digital retail expands, it is expected to play a more prominent role in the growth of the global thermal underwear market.

Global Thermal Underware Segment Analysis

In this report, the Global Thermal Underware Market has been segmented by Product Type, Material Type, Distribution Channel, and Geography.

Global Thermal Underware Market, Segmentation by Product Type

The Global Thermal Underware Market has been segmented by Product Type into Tops, Bottoms and Sets.

Tops, including long-sleeve thermal shirts, turtlenecks, and base layers, are among the most popular items in this market. These products are designed to be worn under regular clothing to provide an extra layer of warmth without adding bulk. The tops segment is driven by consumer demand for versatile winter wear that can be used in a variety of settings, from outdoor sports to casual everyday use. Advances in fabric technology, such as moisture-wicking and breathable materials, have further boosted the appeal of thermal tops, making them suitable for a wide range of activities, including sports and leisure. Additionally, thermal tops often feature ergonomic designs that ensure maximum comfort and mobility, enhancing their functionality for outdoor enthusiasts and athletes.

Bottoms, such as thermal leggings and long johns, are also a crucial segment in the market. These garments provide insulation for the lower body and are frequently worn as a base layer in cold weather. Thermal bottoms are especially popular among consumers participating in winter sports like skiing, snowboarding, and hiking, where full-body warmth is essential. In addition, thermal bottoms are gaining popularity as loungewear, with more consumers seeking comfort and warmth during colder months. Innovations in fit, stretchability, and seamless designs have made these garments more comfortable for prolonged wear, further contributing to their rising demand. The growing trend of athleisure, where sportswear transitions into casual wear, is also propelling the growth of the thermal bottoms segment.

Sets, which include coordinated thermal tops and bottoms sold together, offer consumers a convenient option for full-body warmth. These sets are particularly popular in colder climates where comprehensive insulation is required for daily activities or outdoor work. Thermal underwear sets are often marketed as part of winter collections, appealing to consumers seeking both practicality and value. The rise of e-commerce has further driven the demand for thermal sets, as consumers prefer the convenience of purchasing complete outfits online. Sets are also popular among parents purchasing for children, as they provide an easy solution for keeping young ones warm during winter months. Overall, the market for thermal underwear sets is expected to see continued growth due to the increasing demand for comfortable, functional, and cost-effective winter wear solutions.O

Global Thermal Underware Market, Segmentation by Material Type

The Global Thermal Underware Market has been segmented by Material Type into Cotton, Synthetic, Wool and Others.

Cotton is one of the most commonly used materials in thermal underwear due to its softness, breathability, and affordability. Cotton thermal wear is typically favored for indoor use or milder winter climates, as it provides comfort and warmth without overheating the body. However, cotton has limitations in extreme cold or during physical activity because it retains moisture, which can make the wearer feel cold once the fabric becomes damp. Despite this, cotton thermal underwear remains popular for everyday wear, especially in regions with moderate winters, and is often preferred for its natural feel on the skin.

Synthetic materials, such as polyester, nylon, and spandex blends, dominate a large share of the thermal underwear market, especially for performance-driven consumers. These fabrics are known for their moisture-wicking properties, quick-drying capabilities, and durability, making them ideal for outdoor activities and sports. Synthetic thermal underwear is designed to trap heat while efficiently managing sweat, ensuring that the wearer stays warm and dry during physical exertion. Additionally, synthetics are lightweight and often more form-fitting, offering greater flexibility and comfort for athletes and outdoor enthusiasts. As innovation in fabric technology continues, synthetic thermal wear is evolving with features like odor resistance and enhanced breathability, making it a preferred choice for active individuals and those in colder, more extreme climates.

Wool, particularly merino wool, is highly regarded in the thermal underwear market for its superior insulation, natural moisture-wicking properties, and softness. Merino wool, unlike traditional wool, is fine and non-itchy, making it comfortable for long wear. Wool has the unique ability to regulate body temperature by trapping heat when it’s cold and allowing breathability when the body warms up, making it ideal for both outdoor and indoor use. Additionally, wool is naturally antimicrobial, which helps prevent odor buildup, making it a popular choice for outdoor adventurers and athletes who engage in multi-day activities like hiking or skiing. Although wool thermal underwear tends to be more expensive than cotton or synthetic counterparts, its durability and performance justify its higher price point, appealing to consumers who prioritize both comfort and functionality in extreme weather conditions.

Global Thermal Underware Market, Segmentation by Distribution Channel

The Global Thermal Underware Market has been segmented by Distribution Channel into Store-Based and Non-Store-Based.

Store-based distribution channels, which include department stores, specialty apparel stores, sportswear outlets, and large retail chains, continue to play a vital role in this market. Many consumers prefer shopping for thermal underwear in physical stores where they can touch, feel, and try on garments before making a purchase. This is particularly important for thermal wear, where comfort, fit, and fabric quality are key considerations. Store-based retailers also offer personalized customer service, where shoppers can receive advice on product selection, materials, and sizes. Additionally, retail stores often serve as hubs for seasonal promotions, drawing in customers looking for winter essentials during peak cold seasons. The presence of thermal underwear in popular clothing stores also helps brands reach a wider audience through high-traffic areas.

Non-store-based distribution channels, primarily driven by e-commerce platforms, have experienced rapid growth in recent years. Online shopping offers consumers the convenience of browsing a vast array of thermal underwear products from the comfort of their homes. E-commerce platforms like Amazon, brand websites, and specialized online apparel retailers provide detailed product descriptions, size guides, and customer reviews, helping consumers make informed decisions without needing to visit a physical store. This channel is particularly appealing to tech-savvy shoppers and those looking for niche products or premium brands that may not be available in their local stores. The rise of mobile commerce and fast shipping options has further fueled the growth of online sales, allowing consumers to quickly access a wide range of thermal underwear products from global markets. As e-commerce continues to evolve, online retailers are increasingly offering personalized shopping experiences, such as customized recommendations and virtual fitting rooms, enhancing customer satisfaction and driving further growth in non-store-based sales.

The expansion of both store-based and non-store-based distribution channels highlights the changing preferences of consumers. While many still value the tactile and personalized experience of in-store shopping, the convenience, variety, and competitive pricing offered by online platforms are reshaping the market landscape. Brands are increasingly adopting an omnichannel approach, combining the strengths of physical stores with digital platforms to reach a broader audience. This hybrid model allows consumers to enjoy the best of both worlds, whether they prefer to shop in-person or online, ultimately driving sustained growth in the global thermal underwear market.

Global Thermal Underware Market, Segmentation by Geography

In this report, the Global Thermal Underware Market has been segmented by Geography into five regions; North America, Europe, Asia Pacific, Middle East and Africa and Latin America.

Global Thermal Underware Market Share (%), by Geographical Region, 2024

North America, particularly the United States and Canada, represents a mature and robust market for thermal underwear. The region experiences seasonal cold weather, making thermal wear a staple in winter wardrobes. The demand is further driven by a strong outdoor culture, where activities such as skiing, hiking, and winter sports are popular, leading to consistent growth in the thermal wear segment. Consumers in North America are increasingly favoring high-performance and sustainable thermal underwear, especially products that incorporate advanced fabrics like merino wool and synthetic blends, which provide better moisture management and warmth. As athleisure and performance apparel trends continue to rise, North America is expected to maintain steady growth in this market throughout the decade.

Europe is another significant market for thermal underwear, driven by its diverse climate and long-standing preference for functional winter clothing. Key countries such as Germany, France, and the UK have well-established markets for winter apparel, where consumers prioritize high-quality, durable thermal wear, especially during the colder months. Like North America, Europe’s outdoor lifestyle and active sports culture, particularly in regions near the Alps and Scandinavia, contribute to the consistent demand for thermal wear. Additionally, European consumers are highly attuned to sustainability and eco-conscious products, leading to an increasing preference for natural fibers like organic cotton and merino wool, as well as brands that adhere to ethical manufacturing practices. As e-commerce continues to expand in Europe, the accessibility of a wider range of thermal wear products will likely fuel market growth in the region.

Asia Pacific region, the thermal underwear market is poised for rapid expansion, driven by a combination of growing urbanization, rising disposable incomes, and a growing interest in winter fashion and outdoor activities. China, Japan, and South Korea are major markets in the region, with increasing consumer awareness of the benefits of thermal wear for both everyday use and sports activities. The colder climates in parts of China and Japan, combined with a cultural preference for layering clothing, support the growth of thermal underwear demand. Additionally, with the rise of e-commerce, consumers across Asia Pacific now have access to a wide variety of thermal underwear brands, from affordable synthetic options to premium woolen products. In emerging markets within Southeast Asia, such as Indonesia and Vietnam, where temperatures are generally warmer, thermal wear demand is smaller but growing, particularly among travelers and sports enthusiasts. The **Middle East and Africa**, though still an emerging market, is seeing increasing demand for thermal wear, particularly in countries with colder winter seasons like parts of Turkey and Northern Africa. Lastly, **Latin America**, including countries like Brazil, Argentina, and Chile, shows moderate growth potential, with demand for thermal underwear rising during the colder months, particularly in the Southern Hemisphere. As the global market for thermal underwear continues to expand, regional variations in consumer preferences, climate, and economic factors will shape the trajectory of growth from 2020 to 2030.

This report provides an in depth analysis of various factors that impact the dynamics of Global Thermal Underware Market. These factors include; Market Drivers, Restraints and Opportunities Analysis.

Drivers, Restraints and Opportunity Analysis

Drivers

• Rising demand for winter apparel in colder regions
• Growing awareness of health and comfort benefits

• Increasing participation in outdoor sports and activities - The increasing participation in outdoor sports and activities is a major driver for the global thermal underwear market, as consumers seek high-performance apparel that ensures comfort and protection in cold weather conditions. Outdoor activities like hiking, skiing, snowboarding, and camping require specialized clothing that helps maintain body warmth while wicking moisture away from the skin. Thermal underwear, known for its ability to regulate body temperature and provide insulation without adding bulk, has become essential gear for enthusiasts engaging in these activities. The rising popularity of fitness trends that emphasize year-round outdoor activity, even in colder climates, has significantly boosted demand for thermal apparel, including thermal underwear.

  This growing trend is particularly strong in regions with harsh winters, such as North America, Europe, and parts of Asia, where consumers prioritize thermal wear for their outdoor adventures. As more people embrace an active lifestyle and pursue outdoor sports for leisure, manufacturers of thermal underwear are investing in the development of lightweight, breathable, and moisture-wicking fabrics that enhance both performance and comfort. Technological advancements in fabric construction, such as seamless knitting and layering technologies, allow thermal underwear to provide optimal insulation while ensuring freedom of movement—qualities highly valued by outdoor sports enthusiasts.

  The rise of e-commerce platforms and social media has played a key role in promoting outdoor activities and gear, further increasing the visibility and accessibility of thermal underwear. Influencers and brands dedicated to fitness and outdoor sports often highlight the benefits of technical and performance-based clothing, encouraging more people to invest in high-quality thermal wear. With the continued growth of outdoor recreation as both a hobby and a lifestyle choice, the demand for premium thermal underwear is likely to rise, presenting significant opportunities for manufacturers to cater to a broader audience with innovative, high-performance products.

Restraints

• High production costs for advanced thermal fabrics
• Seasonal demand fluctuations

• Competition from cheaper, synthetic alternatives - Competition from cheaper, synthetic alternatives poses a significant challenge to the global thermal underwear market, particularly for brands that focus on high-quality, natural, or technical fabrics. Synthetic materials, such as polyester and acrylic, are widely used in thermal underwear due to their affordability, ease of production, and adequate insulating properties. These synthetic options offer a cost-effective solution for consumers seeking basic thermal wear, especially in regions with milder winters or for those engaging in less extreme outdoor activities. As a result, price-sensitive consumers often opt for these cheaper alternatives, putting pressure on premium brands that rely on natural materials like wool or advanced fabric technologies to differentiate their products.

  Despite their affordability, synthetic thermal wear can come with certain trade-offs in terms of comfort, durability, and environmental impact. While synthetic fibers provide insulation, they may not offer the same level of moisture-wicking or breathability as natural fibers like merino wool or advanced technical fabrics. Additionally, synthetic materials tend to trap odors and may not be as durable over time, leading to a shorter lifespan compared to higher-quality thermal underwear. However, for consumers who prioritize cost over long-term performance, these issues may be less of a concern, further intensifying competition in the market.

  To address this competition, premium thermal underwear brands are increasingly focusing on innovation, sustainability, and performance to distinguish themselves from lower-priced alternatives. By investing in advanced fabric technologies that combine natural fibers with synthetic blends, manufacturers can offer the best of both worlds—comfort, durability, and environmental responsibility. Additionally, highlighting the eco-friendly and long-lasting qualities of their products can help premium brands appeal to environmentally conscious consumers. In an increasingly competitive market, brands that effectively communicate the value of superior performance, sustainability, and durability will have an edge over cheaper synthetic alternatives.

Opportunities

• Innovation in lightweight and moisture-wicking materials
• Expansion into emerging markets with colder climates

• Growth in e-commerce and online retail - The growth of e-commerce and online retail has significantly impacted the global thermal underwear market, making it easier for consumers to access a wider variety of products. Online platforms have allowed thermal underwear brands to reach broader audiences without the geographical limitations of brick-and-mortar stores. With the rise of digital shopping, consumers can now compare prices, read reviews, and explore different brands, all from the convenience of their homes. This trend has particularly benefited smaller or niche brands that might not have had the resources to compete in traditional retail spaces but can now directly reach consumers through e-commerce.

  The convenience of online shopping has also transformed consumer purchasing behavior, with many opting to buy thermal underwear during seasonal promotions, flash sales, or special offers that are more easily accessible online. E-commerce giants like Amazon, as well as specialized outdoor and apparel retailers, have created competitive marketplaces where consumers can quickly find products that meet their specific needs. This shift has driven more thermal underwear manufacturers to establish an online presence, whether through their own websites or partnerships with third-party retailers, helping them tap into a global market.

  The integration of advanced technologies like artificial intelligence (AI) and augmented reality (AR) in online retail is enhancing the shopping experience for thermal underwear. AI-powered recommendation engines offer personalized product suggestions based on past purchases and preferences, while AR allows customers to visualize how items might fit or look on them before buying. This personalized, interactive shopping experience helps increase consumer confidence in online purchases, driving higher sales. As e-commerce continues to grow, brands that invest in optimizing their online presence, improving digital marketing strategies, and adopting emerging technologies will be well-positioned to capitalize on the expanding global demand for thermal underwear.

Key players in Global Thermal Underware Market include :

• Komar Brands
• Sub Zero Technology Ltd
• Thatchreed Ltd
• Gildan Activewear Inc.
• L.L. Bean Inc.
• Namald? Underwear
• Rothco
• Floso
• Lux Industries Limited
• Aditya Birla Fashion & Retail Limited

In this report, the profile of each market player provides following information:

• Company Overview and Product Portfolio
• Key Developments
• Financial Overview
• Strategies
• Company SWOT Analysis