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Costume designers need to consider movement constraints when designing costumes, eg if the performer needs to be able to dance, bend or climb. Some materials are rigid and restricting and can have health and safety implications if used. Some costume items, eg corsets, may need to appear to be tight-fitting and restrictive without actually constraining the movement of the actor. Costume designers need to know how to make costumes lighter and less restrictive to enable performers to move freely.

As a performer moves around the rehearsal and performance space, the costume must allow them fluid and safe movement. For example, chains, hooks, tails, high heels or the costume length may cause the actor to trip, so this should be considered during the design. Performers may need extra time to get used to the dimensions of the costume to ensure their safety.

Consideration needs to be given to how the performer will get the costume on and off, how long it will take them and whether they will need help, particularly with more unusual costumes, such as creature suits or large restoration dresses.

Materials need to be fireproofed and non-toxic, including any glues used, and sharp adornments, eg brooches, should be used with care. Some materials, such as latex and nickel (found in a lot of jewellery), can cause allergic reactions, so performers should be consulted on this.

Precautions should be taken to prevent injury when using sharp items in the construction of costumes, eg needles, pins and sewing machines. Care should be taken with posture while working on a costume, and the area should be well lit. A first-aid kit should always be fully stocked and available nearby. Sensible clothing and shoes should be worn, and long hair tied back. Liquids and food should be kept away from electrics and from all costumes to prevent staining or damage. Clearing up and storing equipment appropriately will help to prevent damage and spillages.