Custom BJJ Rash Guards: Manufacturing Guide & Worldwide Shipping (2026)

Custom BJJ Rash Guards: Manufacturing Guide & Worldwide Shipping (2026)

By BJJ Sportswear Editorial Team
Manufacturing Expert Review
Last Updated: January 19, 2026

Custom BJJ rash guards represent the fastest-growing segment of no-gi training apparel, with academies, competition teams, and individual athletes demanding personalized designs that reflect their brand identity, with monthly orders ranging from 25-500 units at $18-35 per piece depending on fabric weight (200-260 GSM), printing method (sublimation vs screen print), and customization complexity, making Pakistan-based manufacturers like FitmanPro the preferred choice for worldwide delivery combining premium quality, competitive pricing, and full design flexibility for short-sleeve, long-sleeve, and women’s compression styles serving BJJ, MMA, no-gi grappling, and submission wrestling markets.

Why Custom Rash Guards Matter

Team Identity & Branding

Custom rash guards transform training environments by creating unified team appearance, with 78% of BJJ academies reporting increased student retention when wearing branded gear, while professional competitors gain sponsorship visibility worth $2,000-10,000 annually through logo placement during IBJJF tournaments, ADCC trials, and UFC broadcast events, making personalized rash guards essential investment for serious programs seeking competitive edge and revenue generation through retail sales to students at 40-60% markup from wholesale manufacturing costs.

Performance Requirements

Elite rash guards must survive 300+ training hours annually under extreme conditions including mat friction, sweat exposure, repeated washing cycles (100+ per year), and grappling stress that tears inferior products within weeks, requiring manufacturers to use premium polyester-spandex blends (88-92% polyester, 8-12% spandex), reinforced flatlock stitching at stress points, and professional-grade sublimation that won’t crack, fade, or peel after 50+ wash cycles, specifications only achievable through specialized factories like Pakistan’s Sialkot manufacturing hub where FitmanPro operates with 15+ years combat sports expertise.

Custom Rash Guard Manufacturing Process

Step 1: Design Consultation

FitmanPro’s design team provides free consultation supporting:

• Logo placement optimization (chest, back, sleeves, shoulders)
• Color matching (Pantone accuracy for brand consistency)
• Sponsor integration (multiple logo zones without visual clutter)
• Template library (100+ proven designs adaptable to your brand)
• Mockup previews (3D rendering before production commitment)
• Revision rounds (unlimited design adjustments until approval)

Turnaround: 24-48 hours for initial mockup delivery

Step 2: Fabric Selection

200 GSM Fabric – Lightweight Competition

• Best For: Tournament use, hot climates, speed training
• Feel: Ultra-light, second-skin fit
• Durability: 200-300 training hours
• Price Point: $18-22 per unit (MOQ 50)
• Popular With: Competitors, warm-weather academies

230 GSM Fabric – Standard Training

• Best For: Daily training, all-season use, general academies
• Feel: Balanced weight, comfortable compression
• Durability: 400-500 training hours
• Price Point: $22-28 per unit (MOQ 50)
• Popular With: Most BJJ schools, recreational teams

260 GSM Fabric – Heavy-Duty Professional

• Best For: Intensive training camps, MMA integration, rough grapplers
• Feel: Substantial compression, muscle support
• Durability: 600+ training hours
• Price Point: $28-35 per unit (MOQ 50)
• Popular With: Professional fighters, high-intensity programs

All fabrics feature:

• Moisture-wicking technology (dries 3x faster than cotton)
• Anti-microbial treatment (prevents ringworm/staph)
• 4-way stretch (maintains shape during grappling)
• UV protection (UPF 50+ for outdoor training)
• Reinforced seams (flatlock stitching, won’t chafe)

Step 3: Printing Method

Sublimation Printing (Recommended)

• Process: Dye infused into fabric fibers (becomes part of material)
• Durability: Permanent – never cracks, peels, or fades
• Color Options: Unlimited – full spectrum available
• Design Complexity: No limits – photographic quality achievable
• Wash Cycles: 200+ without degradation
• Cost: Included in base price (no upcharge)
• Best For: Professional teams, retail sales, long-term use

Screen Printing (Budget Option)

• Process: Ink applied to surface layer
• Durability: 50-100 wash cycles before fading
• Color Options: Limited to 4-6 colors per design
• Design Complexity: Simple logos/text only
• Cost: 20% cheaper than sublimation
• Best For: Temporary events, trial runs, extreme budget constraints

FitmanPro Recommendation: 95% of clients choose sublimation for superior longevity and design freedom.

Step 4: Size Range & Fit

Standard Sizing Available:

• Kids: 6, 8, 10, 12, 14 years
• Adults: XS, S, M, L, XL, 2XL, 3XL, 4XL
• Women’s Cut: Tailored fit with adjusted torso/arm proportions

Custom Sizing: Available for teams needing specific measurements (minimum 100 units)

Fit Styles:

• Compression Fit: Tight to body, competition-legal, prevents grip holds
• Athletic Fit: Slightly looser, training comfort, still IBJJF compliant
• Relaxed Fit: Training-only, maximum comfort, not competition approved

Step 5: Additional Customization

Collar Options:

• Standard crew neck
• V-neck (modern aesthetic)
• High collar (extra neck protection)

Sleeve Options:

• Short sleeve (most popular – 70% of orders)
• Long sleeve (no-gi preferred, prevents mat burn)
• Sleeveless (rare, some gyms for conditioning)

Label/Tag Options:

• Custom woven labels (your brand name, care instructions)
• Neck print labeling (no-tag comfort)
• Hang tags (for retail presentation)

Packaging Options:

• Individual poly bags (retail ready)
• Custom branded boxes (premium presentation)
• Bulk carton packaging (wholesale shipments)

Minimum Order Quantities (MOQ)

FitmanPro MOQ Structure:

25-49 Units: $35-40 per piece

• Ideal for small academies, trial designs
• 2-3 week production time
• Standard shipping included

50-99 Units: $28-32 per piece (Most Popular)

• Sweet spot for mid-size academies
• Full customization available
• 2 week production time
• Express shipping option available

100-249 Units: $22-26 per piece

• Large academies, multiple locations
• Priority production scheduling
• Free design revisions
• Volume shipping discounts

250-499 Units: $20-24 per piece

• Distributor/retailer orders
• Dedicated account manager
• Rush production available (7-10 days)
• Custom packaging included

500+ Units: $18-22 per piece (Best Value)

• Brand partnerships, franchises
• Lowest per-unit cost
• Inventory management support
• Global shipping coordination

Note: All prices include sublimation printing, standard sizing, and basic packaging.

Worldwide Shipping From Pakistan

FitmanPro ships to 150+ countries:

North America:

• USA: 14-18 days (DHL Express: 7-10 days)
• Canada: 16-20 days (Express: 8-12 days)
• Shipping Cost: $150-300 for 50-unit orders

Europe:

• UK: 12-16 days (Express: 6-9 days)
• Germany, France, Spain: 14-18 days
• Shipping Cost: $180-350 for 50-unit orders

Australia/New Zealand:

• 16-22 days (Express: 10-14 days)
• Shipping Cost: $200-400 for 50-unit orders

Asia:

• UAE, Saudi Arabia: 8-12 days
• Singapore, Malaysia: 10-14 days
• Shipping Cost: $120-250 for 50-unit orders

South America:

• Brazil: 20-25 days
• Argentina, Chile: 18-24 days
• Shipping Cost: $220-450 for 50-unit orders

Express Shipping Available: 50% faster delivery, 30-40% higher cost

Customs & Import: FitmanPro provides complete documentation for smooth customs clearance in all destinations.

Quality Control Process

FitmanPro 7-Point Quality Check:

1. Fabric Inspection – Every roll tested for GSM weight, stretch recovery, colorfastness
2. Print Verification – Color accuracy checked against approved mockup
3. Stitch Quality – Flatlock seams inspected for strength, no loose threads
4. Size Accuracy – Random sample measurement vs. size chart specifications
5. Wash Test – Sample pieces washed 10 cycles to verify print durability
6. Final Inspection – Each piece individually checked before packaging
7. Photo Documentation – Pre-shipment photos sent to client for approval

Defect Rate: <0.5% (industry average: 2-3%)

Warranty: Free replacement for manufacturing defects within 30 days of delivery

Pricing Comparison: Pakistan vs Other Countries

Why Pakistan Wins:

• 30-50% lower cost than Western manufacturers
• Comparable/superior quality to China with better communication
• Faster turnaround than most competitors
• Sialkot’s 40+ year combat sports manufacturing legacy
• English-speaking design teams (no language barriers)

Case Study: Successful Custom Rash Guard Programs

Example 1: Mid-Size BJJ Academy (150 students)

Order Details:

• 100 long-sleeve rash guards (academy logo + sponsor)
• 230 GSM fabric, sublimation print
• Cost: $2,600 ($26 per piece including shipping)
• Retail Price: $65 per piece to students
• Profit: $3,900 (150% markup)

Results:

• 72% of students purchased within 3 months
• Team unity increased (visible during competitions)
• Sponsor secured $5,000 annual deal for logo placement

Example 2: Competition Team (25 athletes)

Order Details:

• 50 short-sleeve rash guards (25 for team, 25 retail inventory)
• 200 GSM lightweight, team colors + athlete names
• Cost: $1,500 ($30 per piece)
• Sold 23/25 retail units at $60 each
• Profit: $1,380 + equipped entire team

Results:

• Professional appearance at IBJJF tournaments
• 3 new sponsors approached team after event visibility
• Retail sales covered team’s equipment costs

Example 3: MMA Gym (500 members, multi-location)

Order Details:

• 300 rash guards (long + short sleeve mix)
• 260 GSM heavy-duty, multiple designs
• Cost: $6,900 ($23 per piece bulk discount)
• Retail: $70 per piece
• Projected Revenue: $21,000 (if 100% sold)

Strategy:

• Required gear for no-gi classes (drives guaranteed sales)
• New designs every 6 months (keeps collection fresh)
• Pre-order system (no inventory risk)

How to Order From FitmanPro

Step-by-Step Process:

1. Initial Contact (Day 1)

• Email: [Contact form on fitmanpro.com]
• Instagram DM: @fitman.pro
• Provide: Team name, quantity needed, design ideas/logo files

2. Design Phase (Days 2-5)

• Receive mockup within 48 hours
• Request revisions (unlimited)
• Approve final design

3. Quote & Payment (Days 6-7)

• Receive detailed quote (unit price, shipping, total)
• Payment options: PayPal, Wire Transfer, Western Union
• 50% deposit to start production, 50% before shipping

4. Production (Days 8-21)

• 2-week standard production time
• Progress updates every 3-4 days
• Pre-shipment photos for approval

5. Shipping & Delivery (Days 22-40)

• Express: 7-10 days
• Standard: 14-20 days
• Tracking number provided
• Customs clearance support

Total Timeline: 30-40 days from first contact to delivery (Express: 25-30 days)

Design Tips for Maximum Impact

Logo Placement Best Practices:

Chest Logo (Primary):

• Ideal Size: 4″x4″ to 6″x6″
• Placement: Center chest or left/right chest
• Visibility: High during training, visible in photos

Back Logo (Secondary):

• Ideal Size: 10″x10″ to 12″x12″
• Placement: Upper back (between shoulder blades)
• Visibility: Dominant in competition photos/videos

Sleeve Logos (Tertiary):

• Ideal Size: 2″x2″ to 3″x3″ per sleeve
• Placement: Outer bicep/shoulder area
• Visibility: Sponsor placement, side angle photos

Sponsor Integration:

• Limit to 4-6 sponsors maximum (avoid cluttered look)
• Size hierarchy: Main sponsor larger, secondary sponsors smaller
• Placement: Shoulders, lower back, sleeves
• IBJJF logo size rules: Check current regulations for competition legality

Color Psychology:

Black – 40% of orders

• Professional, hides sweat stains, universally flattering
• Best with: Bright accent colors (red, white, gold)

Navy Blue – 25% of orders

• Traditional BJJ, conservative, team-friendly
• Best with: White, gold, silver accents

White – 15% of orders

• Clean aesthetic, shows dirt (forces discipline)
• Best with: Bold colors (black, red, royal blue)

Custom Colors – 20% of orders

• Brand-specific (match academy colors exactly)
• Requires Pantone color codes for accuracy

Maintenance & Care Instructions

Washing (Extend Lifespan to 500+ Hours):

• Cold water wash only (hot water damages elasticity)
• Turn inside out (protects print from abrasion)
• Gentle/delicate cycle (reduces fabric stress)
• Air dry only (dryer heat destroys spandex fibers)
• No fabric softener (clogs moisture-wicking pores)
• Separate from gi/rough fabrics (prevents pilling)

Storage:

• Hang or fold flat (avoid creasing)
• Cool, dry place (prevents mildew)
• Never leave wet in gym bag (bacterial growth)

Stain Removal:

• Blood: Cold water + hydrogen peroxide immediately
• Mat dirt: Pre-soak in cold water before wash
• Stubborn stains: OxiClean soak (no bleach)

Full care guide: How to Wash BJJ Gi (same principles apply)

Frequently Asked Questions

Q: Can I order just 10 rash guards for my team?
A: FitmanPro’s minimum is 25 units for custom orders. For smaller quantities, consider purchasing from existing BJJ brands with ready-made designs.

Q: How long does sublimation printing last?
A: Permanent. The dye bonds with fabric fibers and will last the entire lifespan of the rash guard (500+ training hours or 200+ wash cycles).

Q: Are FitmanPro rash guards IBJJF legal?
A: Yes, if designed to IBJJF specifications – 10% black/navy/white fabric minimum, no offensive imagery, proper fit. FitmanPro’s team ensures compliance during design phase.

Q: Can I get samples before bulk order?
A: Yes. Single samples available for $45-60 including shipping. Sample cost credited toward bulk order if placed within 60 days.

Q: What if I need rush production?
A: Express production available for orders 50+ units: 7-10 day production + express shipping (7-10 days) = 14-20 day total. Additional cost: 25% upcharge on production.

Q: Do you offer women’s specific sizing?
A: Yes. Women’s cut available with adjusted torso length, shoulder width, and arm proportions. Same pricing as standard sizing.

Q: Can I mix sizes in one order?
A: Yes. Provide size breakdown (e.g., 5 Small, 15 Medium, 20 Large, 10 XL) and FitmanPro produces exact quantities needed.

Q: What payment methods do you accept?
A: PayPal (buyer protection), Wire Transfer (best for large orders), Western Union (fastest). 50% deposit starts production, 50% balance before shipping.

Q: Are there import duties/taxes?
A: Depends on destination country. Most countries charge 0-15% customs duty on sportswear. FitmanPro provides all documentation to minimize charges. USA: Typically $0-50 for 50-unit orders.

Q: What if some pieces have defects?
A: FitmanPro replaces defective items free of charge. Defect rate is <0.5%. If issues occur, photo documentation triggers immediate replacement production.

Why Choose FitmanPro for Custom Rash Guards

15+ Years Manufacturing Excellence

• Sialkot, Pakistan’s premier combat sports hub
• 10,000+ custom orders completed worldwide
• Clients in 60+ countries across 6 continents
• Partnerships with professional MMA fighters, BJJ academies, national teams

Unmatched Quality-to-Price Ratio

• 30-50% lower than Western manufacturers
• Superior quality to most Chinese factories
• Premium fabrics sourced from certified suppliers
• ISO-compliant production facility

Customer-Centric Service

• Free design consultation and unlimited revisions
• 24-48 hour mockup turnaround
• English-speaking design team (no language barriers)
• Transparent pricing (no hidden fees)
• Post-delivery support for reorders and modifications

Global Shipping Expertise

• 150+ countries serviced
• Complete customs documentation
• Package tracking from factory to doorstep
• Shipping insurance included on all orders

Flexible Order Sizes

• MOQ 25 units (lowest in industry for premium custom)
• Scalable pricing (better rates as volume increases)
• Mix-and-match sizes in single order
• No setup fees or design charges

Related Resources

• What is BJJ? – Complete introduction for beginners
• Gi vs No-Gi Training – Understanding rash guard necessity
• Benefits of Using Rash Guards – Why every grappler needs them
• BJJ Hygiene Tips – Preventing skin infections
• Prevent Ringworm & Staph – Rash guard protection
• High Quality Rashguards for BJJ – Ready-made options comparison
• What is IBJJF? – Competition gear regulations
• Top 10 BJJ Gyms in New York – Academies using custom gear

Custom BJJ Rash Guards – Transform your academy’s brand identity, generate retail revenue, and equip your team with professional-grade gear manufactured by Pakistan’s premier combat sports factory with 15+ years expertise serving worldwide clients.

Get your free design mockup today: Contact FitmanPro