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Many beginners sew theater costumes way too loosely or use the wrong fabric because they think it's "just for looking at." That's a huge mistake - the pieces have to hold up through every movement, every jump, and every turn. Cheap fabrics tear easily, and loose seams mean your costume falls apart on stage. Plus, don't assume you can get away with standard patterns. Theater often needs special cuts and modifications.
What matters is using sturdy fabrics - cotton, linen, or synthetics that don't fall apart right away. Seams need to be doubled or finished with a zigzag stitch so nothing comes undone. When you're actually sewing, pay attention to fit too: the costume has to sit snug enough that it doesn't slip, but loose enough that you can breathe and move in it. Try everything on multiple times and have someone watch you do the character's key movements.
Also think about how it'll look from several meters away - fine details you worked on often won't even be visible from the stage. Colors and cuts need to be bold and clear. And here's something practical: pockets are your friend, even if they're not visible in the scene, the actor needs them to get onstage from the wings. Take your time sewing it; don't do everything the night before opening night.
The key thing is to choose sturdy fabrics that can take a beating - the costumes need to survive multiple performances and moves without tearing. Make sure there's plenty of room to move, especially in the arms and legs, so the actors aren't restricted, and sew everything properly with strong seams, not just on the surface. Colors should work under stage lighting and stand out from the stage backdrop, so it's worth testing them under actual light beforehand. If you can, build in velcro or magnets for quick changes, since that saves a crazy amount of time backstage during costume switches.
The biggest mistake is not sealing the seams - especially for costumes that need to handle a lot of movement. When you're cutting fabrics that tend to fray, you need either zigzag stitches on all edges or even better: fabric sealant (you can find it at fabric stores). That'll save you real headaches later if something suddenly starts falling apart during a performance.
A practical tip I haven't seen mentioned yet: sew double thread at critical stress points (armpits, crotch, armholes). Sounds simple, but most people don't do it - and that's exactly where costumes love to rip. You should also plan for bias tape or reinforcements at load-bearing points, especially if cords or weights are hanging from them.
What the others have already mentioned is absolutely right: the fabric has to be durable and freedom of movement is crucial. But here's one more detail - test the costumes during rehearsals before the actual performances. Have the actors train with them, dance, go into deep squats. Better to patch things up during rehearsal than have something fall apart on stage.
People often underestimate how important the right fit is - a costume that sits perfectly in the wardrobe can shift or feel tight on stage when the actor moves. Make sure you fit it on the person who'll be wearing it, and have them rehearse in it too - jumping around, crouching down, throwing their arms up. And another thing: closures like buttons or zippers need to be absolutely rock solid, otherwise you'll have a disaster on your hands during a performance.
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