Thermal Underwear Market – Global Industry Size, Share, Trends, Opportunity, and Forecast, Segmented By Product Type (Tops, Bottom, Sets), By End User (Men, Women), By Sales Channel (Supermarket/Hypermarket, Specialty Stores, Online, Others), By Region & Competition, 2020-2030F

Market Overview

The Global Thermal Underwear Market, valued at USD 8.81 Billion in 2024, is projected to experience a CAGR of 4.99% to reach USD 11.80 Billion by 2030. Thermal underwear comprises specialized garments, including tops and bottoms, designed as a base layer to provide insulation and efficiently retain body heat in cold conditions. These items are typically constructed from synthetic fibers, wool, or blended fabrics, offering key attributes such as moisture-wicking properties, breathability, and enhanced durability. The market's expansion is fundamentally driven by increasing consumer awareness regarding thermal comfort and the benefits of layering for effective insulation, alongside growing participation in outdoor activities and winter sports globally. Advancements in textile technology, leading to improved material performance, further support this growth.

However, the global thermal underwear market faces a notable challenge from its inherent dependence on seasonal demand, which can lead to fluctuations in sales and complicate inventory management for manufacturers. Despite the broader category of apparel sales, specific data for the global thermal underwear market from industrial associations remains limited. Nevertheless, according to the Outdoor Industry Association, in 2024, apparel sales within the U. S. outdoor retail market, a segment including thermal underwear, remained flat at USD 15.7 billion.

Key Market Drivers

The increasing participation in outdoor and sports activities significantly propels the global thermal underwear market. As more consumers engage in pursuits such as skiing, snowboarding, hiking, and other cold-weather recreational activities, the demand for specialized base layers designed to provide warmth and moisture management intensifies. These garments are considered essential for comfort and performance in challenging conditions, leading to consistent product uptake. According to Snowsports Industries America, in September 2023, for the 2022-23 season, 29.9 million people participated in a winter sports activity in the U. S. , reflecting a substantial rise in consumer engagement within a key segment of the outdoor market.

Further expanding the market is the continuous advancement in fabric technology and material innovation. Developments in textiles now offer enhanced insulation properties, superior breathability, lighter weight, and improved moisture-wicking capabilities, alongside growing commitments to sustainable product offerings. These innovations directly contribute to higher product performance and consumer satisfaction, driving both replacement purchases and new adoption of technical apparel. According to Good On You, in May 2024, the Material Innovation Initiative reported that globally in 2023, 144 companies were dedicated to researching and developing next-generation materials, demonstrating a strong industry-wide focus on material science to meet evolving consumer expectations. Overall, the textile industry underpinning these innovations remains substantial, with global fiber production for apparel, home textiles, and footwear reaching 124 million tonnes in 2023, as stated by Textile Exchange's Materials Market Report in September 2024.

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Key Market Challenges

The global thermal underwear market is significantly hampered by its inherent dependence on seasonal demand. This seasonality creates pronounced fluctuations in sales volumes, presenting substantial challenges for manufacturers in forecasting and production planning. Periods of high demand during colder months are often followed by extended periods of reduced sales, leading to uneven revenue streams. This volatility complicates inventory management, compelling manufacturers to either hold excess stock during off-peak seasons, incurring storage costs and potential depreciation, or risk understocking during peak times, resulting in lost sales opportunities.

This sales inconsistency directly impedes market expansion. For instance, according to the Outdoor Industry Association, overall apparel sales within the U. S. outdoor retail market, which encompasses thermal underwear, experienced a 2.5 percent decline in units sold in 2024, despite dollar sales remaining flat. This unit sales reduction indicates a volume challenge exacerbated by the ebb and flow of seasonal purchasing patterns. Further, the total U. S. outdoor retail market, including apparel, experienced a 3 percent decline in 2023. Such annual and unit-based fluctuations underscore how seasonal demand introduces instability, hindering consistent growth and efficient resource allocation across the thermal underwear sector.

Key Market Trends

The Global Thermal Underwear Market is significantly shaped by the integration of smart and heated apparel. This trend represents a notable advancement beyond passive insulation, encompassing garments with active heating elements, embedded sensors for biometric data collection, and connectivity features. These technological enhancements offer wearers advanced comfort and performance in demanding conditions, broadening the market appeal beyond traditional cold-weather enthusiasts. According to the Advanced Textiles Association in its "2024 State of the Textile Industry" report, smart fabrics and textiles were identified as a market area poised for growth, with 20% of surveyed industry professionals indicating its potential. This strategic shift enables thermal underwear to serve new applications such as health monitoring and sophisticated personal climate control. For instance, in November 2022, Sensoria, a USA-based company, launched a wearable tele-rehabilitation platform, showcasing the expanding capabilities of smart textile integration in practical applications.

Another pivotal trend influencing the market is the integration of athleisure and style. This involves thermal underwear evolving from strictly functional base layers to versatile garments suitable for visible wear in various casual and active settings. The emphasis here is on combining performance characteristics with enhanced aesthetics, softer fabrications, and adaptable designs that cater to modern lifestyles. This expansion attracts a wider consumer base interested in comfortable yet fashionable apparel for daily wear, not solely for extreme outdoor activities. The International Health, Racquet & Sportsclub Association reported that global health club membership increased by 7.8% in 2023, reaching 184 million, illustrating the expanding active lifestyle that drives athleisure demand. Complementing this, LILYSILK unveiled its SILKERRY™ Collection in August 2025, featuring an activewear line made from silk-enhanced terry fabric, exemplifying the fusion of luxurious materials with athletic design for everyday elegance.

Segmental Insights

The Online segment is a key growth driver within the Global Thermal Underwear Market, experiencing rapid expansion primarily due to unparalleled consumer convenience and accessibility. E-commerce platforms offer a broad spectrum of products from numerous brands, enabling consumers to easily compare options and make informed purchasing decisions. This digital shift is further propelled by the increasing prevalence of direct-to-consumer models, which allow brands to foster direct engagement with their customer base and swiftly adapt to evolving market trends. Additionally, the perceived advantages of competitive pricing and streamlined distribution via online channels significantly contribute to their accelerated adoption among consumers.

Regional Insights

Europe stands as a leading region in the global thermal underwear market, demonstrating a significant impact on its overall trajectory and development. This dominance is primarily driven by the prevalence of frigid temperatures across numerous European nations, including the UK, Russia, and Germany, creating consistent consumer demand for effective insulation. Furthermore, the robust and expanding apparel industry within Europe fosters continuous product innovation, responding to evolving consumer preferences and a heightened demand for advanced sports thermal clothing. The region also exhibits a strong consumer inclination towards sustainable and eco-friendly fabrics, influencing product development and market trends.

Recent Developments

• In April 2024, 1836 Total Commerce, the parent company for Thermajohn and Thermajane thermal wear brands, launched their new Merino Wool Thermal Collection. This collection introduced thermal underwear sets, tops, and bottoms for men, women, and children. The selection was crafted from merino wool, chosen for its superior thermal qualities, including warmth, breathability, and comfort. This strategic product launch aimed to enhance the company's offerings with a premium fabric, providing consumers with a luxurious option for cold-weather apparel.

Key Market Players

• PVH Corporation
• HanesBrands Inc.
• Marks and Spencer plc
• Jockey International Inc
• Under Armour Inc.
• VF Outdoor LLC
• L.L.Bean Inc.
• Fruit of the Loom Inc.
• Miller Optik GmbH
• Thermajohn

Report Scope:

In this report, the Global Thermal Underwear Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

• Thermal Underwear Market, By Product Type:

o   Tops

o   Bottom

o   Sets

• Thermal Underwear Market, By End User:

o   Men

o   Women

• Thermal Underwear Market, By Sales Channel:

o   Supermarket/Hypermarket

o   Specialty Stores

o   Online

o   Others

• Thermal Underwear Market, By Region:

o   North America

§  United States

§  Canada

§  Mexico

o   Europe

§  France

§  United Kingdom

§  Italy

§  Germany

§  Spain

o   Asia Pacific

§  China

§  India

§  Japan

§  Australia

§  South Korea

o   South America

§  Brazil

§  Argentina

§  Colombia

o   Middle East & Africa

§  South Africa

§  Saudi Arabia

§  UAE

Competitive Landscape

Company Profiles: Detailed analysis of the major companies presents in the Global Thermal Underwear Market.

Available Customizations:

Global Thermal Underwear Market report with the given market data, TechSci Research offers customizations according to a company's specific needs. The following customization options are available for the report:

Company Information

• Detailed analysis and profiling of additional market players (up to five).

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