PurposeThe circular design process in contemporary fashion design, from two-dimensional (2D) sketching and pattern making to three-dimensional (3D) prototypes, can be facilitated by virtual prototyping. Virtual pressure representations on avatars provide visual and quantitative information regarding garment fit and comfort, which are particularly important for active wear. The purpose of this study is to investigate the benefits of using avatars in active poses from 3D body scans and the use of digital 3D tools for the design process and the prediction of fit of active wear.Design/methodology/approachThis research initially explores virtual fit of cycling wear in active poses and compares the actual pressure values from humans with virtual pressure maps on custom avatars made from body scans in cycling poses across a range of sizes.FindingsSimilar fit results were achieved visually in both the standing and cycling poses. However, the comparisons showed no correlation between the actual and virtual pressure data. Of the 32 cases representing different combinations of the parameters of this research (four sizes, two garment types, four active poses), the differences were significant. The results suggest that, rather than providing a direct correlation with pressure values on the body, the main value of avatar data is in providing comparative visual support for fit evaluation.Originality/valueThe approach taken in this research, which considers the active pose and the size range, potentially contributes to the improvement of virtual fit technology, and its more effective use in apparel product development and fit evaluation.