Sell Gym Merch in 2025: Zero-Inventory Model Explained

Gone are the days of ordering boxes of shirts, hoping they sell, and marking down leftovers months later. The most profitable gyms in 2025 are running zero inventory merch drops — a system where every item is paid for before you print a single shirt.

At Forever Fierce, we’ve helped over 1,500 gyms make merch a reliable revenue stream using this exact approach. Here’s the step-by-step playbook you can use to launch your most profitable merch drop yet.

Step 1 – Pick the Right Product Mix

• Seasonal Relevance: Hoodies and long sleeves crush in the fall/winter; tanks and lightweight tees fly in spring/summer.

• Proven Staples: A unisex tee, a women’s-specific cut, and one premium seasonal item.

• Limit Choice: Too many options kills urgency. 2–4 styles max is the sweet spot.

Pro Tip: We build your product mix directly into The Apparel Plan, so every drop is optimized for profit and member interest.

Step 2 – Launch with a Short Preorder Window

• Ideal Duration: 5–7 days. Long enough for everyone to see it, short enough to create FOMO.

• Payment First: Members order and pay upfront — no guessing sizes or risking leftover stock.

• Clear Deadline: Every promo piece should remind them exactly when the preorder closes.

Step 3 – Use a Proven Launch System

You can’t just post once and hope for sales. Our most successful gyms:

• Send 3–4 emails over the preorder week.

• Post daily social media reminders with different angles (design reveal, sizing tips, “last chance” push).

• Display physical samples at the gym so members can touch, try, and get excited.

Marketing Support We Provide:

• Pre-written email templates.

• Social media graphics sized for Instagram, Facebook, and Stories.

• Flyers and posters for the gym.

Step 4 – Close the Window & Print

Once the preorder ends:

1. Lock the orders.

2. Send final counts to production.

3. Get printing.

With Forever Fierce, production and delivery are about 2 weeks from preorder close — fast enough to keep excitement high.

Step 5 – Deliver Like It’s an Event

When orders arrive:

• Bag them individually with names for easy handout.

• Announce pickup day in your gym’s email and social channels.

• Turn handout day into a mini celebration — members will post photos and wear their gear immediately, fueling demand for your next drop.

Why the Zero Inventory Model Works

• No Risk: Every piece is already sold and paid for.

• Better Cash Flow: No money tied up in dead stock.

• Higher Profit: No markdowns to clear leftovers.

• Easier Planning: Preorders tell you exactly what to order.

Forever Fierce Makes It Turnkey

The system above is built into our Apparel Plan — we handle the design, launch materials, production, and delivery so you can focus on running your gym.
You end up with a sold-out merch drop, zero wasted cash, and a plan you can run season after season.

Ready to run your most profitable merch drop yet?
Book your free Apparel Plan call here and let’s make it happen.