Custom BJJ Gi: Complete Manufacturing Guide (2026)

Custom BJJ Gi: Complete Manufacturing Guide (2026)

By BJJ Sportswear Editorial Team
Manufacturing Expert Review
Last Updated: January 21, 2026

Custom BJJ gis represent the most profitable segment of Brazilian Jiu-Jitsu apparel manufacturing, with academies, competition teams, and private label brands ordering 25-500+ units at $45-85 per gi depending on weave type (pearl, gold, single, double), fabric weight (350-550 GSM), and customization complexity including embroidery, patches, contrast stitching, and sponsor logos, making Pakistan-based manufacturers like FitmanPro in Sialkot the global leader for premium quality at competitive wholesale pricing with IBJJF-legal specifications (white, blue, black colors only), worldwide shipping to 150+ countries, and complete white-label/private label solutions serving BJJ academies, professional competitors, distributors, and emerging brands seeking 40-60% retail markup potential on custom kimono orders.

Why Custom BJJ Gis Drive Academy Revenue

Retail Profit Potential

BJJ academies ordering custom gis generate substantial revenue through student sales, with 100-unit orders costing $4,500-6,500 wholesale ($45-65 per gi) selling to students at $120-180 retail price ($12,000-18,000 total revenue), producing $5,500-11,500 net profit per production run while creating unified team appearance that increases student retention by 35-50% according to academy owner surveys, with successful programs running 2-4 production cycles annually generating $22,000-46,000 additional income beyond monthly membership fees, making custom gi programs essential revenue streams for sustainable academy growth.

Brand Identity & Competition Presence

Custom gis transform competition presence by creating instantly recognizable team identity during IBJJF tournaments, with professional embroidered patches, academy logos, and sponsor placements generating $3,000-15,000 annual sponsorship revenue for elite teams through brand visibility during podium ceremonies, match footage, and social media content, while students wearing matching custom gis report 68% higher sense of belonging and commitment to training according to sports psychology research, directly correlating to 12-18 month longer average student retention versus academies without branded uniform programs.

Custom BJJ Gi Manufacturing Process

Step 1: Design Consultation & Mockup

FitmanPro’s experienced design team provides comprehensive customization consultation including:

Logo Placement Options:

• Chest embroidery (3″x3″ to 5″x5″ – most visible)
• Shoulder patches (left/right, woven or embroidered)
• Back embroidery (8″x8″ to 12″x12″ – dominant branding)
• Sleeve patches (4″x4″ – sponsor placement)
• Pant leg embroidery (vertical academy name)
• Lapel embroidery (custom text or logo)

Patch Types Available:

• Direct embroidery (permanent, premium appearance)
• Woven patches (traditional look, removable option)
• Rubber/PVC patches (3D effect, modern aesthetic)
• Sublimated patches (photographic detail capability)
• Combination designs (multiple patch types on one gi)

Color Schemes:

• IBJJF-legal colors: White, blue, black (competition approved)
• Custom accent colors (contrast stitching, piping, inner lining)
• Pantone matching (exact brand color replication)
• Multi-color embroidery (up to 12 thread colors available)

Design Mockup Process:

• Initial concept: 24-48 hours delivery
• Unlimited revisions included
• 3D rendering preview (see exact final appearance)
• Sizing chart customization
• Label/hang tag design included

Step 2: Fabric & Weave Selection

Pearl Weave (Most Popular – 70% of Orders)

350 GSM Pearl Weave – Lightweight Competition

• Best For: Tournament use, hot climate training, speed-focused practitioners
• Characteristics: Breathable honeycomb pattern, quick-drying, IBJJF approved
• Durability: 2-3 years daily training (600-800 hours)
• Shrinkage: 2-3% (pre-shrunk options available)
• Price Range: $48-58 per gi (MOQ 50 units)
• Popular With: Competitors, year-round tournament athletes

450 GSM Pearl Weave – Standard Training

• Best For: Daily academy training, all-season use, balanced performance
• Characteristics: Durable weave, maintains shape, professional appearance
• Durability: 3-4 years daily training (1,000-1,200 hours)
• Shrinkage: 3-4% (minimal with proper care)
• Price Range: $52-65 per gi (MOQ 50 units)
• Popular With: Most academies, recreational to serious practitioners
• FitmanPro Recommendation: Best value for academy programs

550 GSM Pearl Weave – Heavy-Duty Professional

• Best For: Intensive training, rough grapplers, longevity priority
• Characteristics: Thick, substantial feel, maximum durability
• Durability: 4-5 years daily training (1,500+ hours)
• Shrinkage: 4-5% (expect significant initial shrink)
• Price Range: $58-72 per gi (MOQ 50 units)
• Popular With: Professional fighters, hard-training academies

Gold Weave (Premium Option)

450-500 GSM Gold Weave

• Best For: Luxury feel, traditional aesthetic, premium academies
• Characteristics: Diagonal weave pattern, soft yet durable, prestige appearance
• Durability: 3-4 years (1,000-1,200 hours)
• Price Range: $55-70 per gi (MOQ 50 units)
• Popular With: High-end academies, private label brands

Single Weave (Budget Option)

350-400 GSM Single Weave

• Best For: Beginner programs, loaner gis, extreme budget constraints
• Characteristics: Lightweight, less durable, basic construction
• Durability: 1-2 years (300-500 hours)
• Price Range: $38-48 per gi (MOQ 50 units)
• Popular With: Kids programs, trial membership gis

Double Weave (Heavy-Duty Traditional)

650-750 GSM Double Weave

• Best For: Cold climate training, traditional Japanese feel, ultra-durability
• Characteristics: Very heavy, warm, extremely durable, slow-drying
• Durability: 5+ years (2,000+ hours)
• Price Range: $65-85 per gi (MOQ 50 units)
• Popular With: Traditional academies, northern climates
• Note: Less popular due to weight; 5% of modern orders

Pants Fabric Options

Ripstop Pants (Modern Standard)

• Lightweight, tear-resistant grid pattern
• Quick-drying, minimal shrinkage
• 90% of academy orders choose ripstop
• Reinforced knees available (+$3/gi)

Canvas/Twill Pants (Traditional)

• Heavier cotton weave
• Traditional feel, slower drying
• 10% of orders (traditionalists)

Step 3: Customization Details

Embroidery Specifications

Included in Base Price:

• Chest logo (up to 5″x5″)
• Back logo (up to 10″x10″)
• One sleeve patch (left or right)
• Pant leg embroidery (academy name)

Additional Customization (+$5-12 per gi):

• Both sleeve patches
• Lapel embroidery
• Custom inner lining color
• Contrast stitching (white gi with black stitching)
• Individual athlete names (roster embroidery)
• Multiple back designs (different belt ranks)

Embroidery Thread Quality:

• Premium polyester thread (colorfast, won’t fade)
• 12+ color options available
• High-density stitching (professional appearance)
• Reinforced backing (won’t pull out during training)

Patch Options

Woven Patches:

• Traditional appearance
• Sewn onto gi (removable for washing if desired)
• Unlimited colors, intricate detail
• Cost: Included in base pricing for 2-3 patches

Rubber/PVC Patches:

• 3D raised appearance
• Modern aesthetic
• Waterproof, extremely durable
• Cost: +$4-8 per patch depending on size

Embroidered Patches:

• Premium professional look
• Direct embroidery onto gi fabric
• Most durable option (permanent)
• Cost: Included in standard customization

Belt Rank Customization

Many academies order different designs per belt level:

White Belt Gis: Basic academy logo only ($45-55/gi)
Blue Belt Gis: Logo + 1 sponsor patch ($50-60/gi)
Purple Belt Gis: Logo + 2 sponsor patches + stripe ($55-65/gi)
Brown Belt Gis: Full customization + name embroidery ($60-72/gi)
Black Belt Gis: Premium design + instructor designation ($65-85/gi)

Step 4: Sizing & Fit Customization

Standard Size Range

Kids Sizes:

• M000 (3-4 years)
• M00 (5-6 years)
• M0 (7-8 years)
• M1 (9-10 years)
• M2 (11-12 years)
• M3 (13-14 years)
• M4 (15-16 years)

Adult Sizes:

• A0 (5’2″-5’5″, 120-140 lbs)
• A1 (5’5″-5’8″, 140-160 lbs)
• A1L (5’8″-5’11”, 140-160 lbs – long)
• A2 (5’8″-5’11”, 160-180 lbs)
• A2L (5’11”-6’1″, 160-180 lbs – long)
• A3 (5’11”-6’1″, 180-200 lbs)
• A3L (6’1″-6’3″, 180-200 lbs – long)
• A4 (6’1″-6’3″, 200-220 lbs)
• A5 (6’3″+, 220+ lbs)

Women’s Specific Cuts:

• F1, F2, F3, F4 (tailored fit for female body proportions)
• Shorter jacket length
• Narrower shoulders
• Adjusted pant rise

Custom Sizing (100+ Unit Orders)

For large academies or brands, FitmanPro offers complete custom sizing:

• Create unique size chart matching your demographic
• Adjust jacket/pant lengths independently
• Customize sleeve/pant widths
• Perfect for teams with specific athlete body types

Competition Fit vs Training Fit

Competition Fit (IBJJF Regulation):

• Sleeves 5cm from wrist when arm extended
• Jacket reaches mid-thigh minimum
• Pants 5cm above ankle bone maximum
• Tight fit prevents opponent grips
• 60% of academy orders

Training Fit (Relaxed Comfort):

• Slightly looser for drilling comfort
• Extended sleeve/pant lengths
• More forgiving sizing
• 40% of academy orders

Minimum Order Quantities & Pricing

FitmanPro MOQ Structure:

25-49 Units (Small Academy/Team)

Pearl Weave 450 GSM: $65-75 per gi
Total Investment: $1,625-3,675
Production Time: 3-4 weeks
Best For: Small academies (30-80 students), trial programs
Retail Potential: $3,000-7,350 (at $120/gi retail)
Profit: $1,375-3,675 (84-100% markup)

50-99 Units (Most Popular – Mid-Size Academy)

Pearl Weave 450 GSM: $52-65 per gi
Total Investment: $2,600-6,435
Production Time: 2-3 weeks
Best For: Mid-size academies (80-150 students)
Retail Potential: $6,000-11,880 (at $120/gi retail)
Profit: $3,400-5,445 (130-145% markup)
Volume Sweet Spot: Best price-to-quality ratio

100-249 Units (Large Academy/Multi-Location)

Pearl Weave 450 GSM: $48-58 per gi
Total Investment: $4,800-14,442
Production Time: 2-3 weeks (priority scheduling)
Best For: Large academies (150+ students), 2-3 locations
Retail Potential: $12,000-29,880 (at $120/gi retail)
Profit: $7,200-15,438 (150-270% markup)
Perks: Free sample gi, priority production, dedicated account manager

250-499 Units (Distributor/Franchise)

Pearl Weave 450 GSM: $45-54 per gi
Total Investment: $11,250-26,946
Production Time: 3-4 weeks
Best For: Franchise networks, regional distributors, emerging brands
Retail Potential: $30,000-59,880 (at $120/gi retail)
Profit: $18,750-32,934 (166-290% markup)
Perks: Rush production available (2 weeks), custom packaging, volume shipping discounts

500-999 Units (Private Label Brand)

Pearl Weave 450 GSM: $42-50 per gi
Total Investment: $21,000-49,950
Production Time: 4-5 weeks
Best For: Established brands, online retailers, international distributors
Retail Potential: $60,000-119,880 (at $120/gi retail)
Profit: $39,000-69,930 (185-333% markup)
Perks: Custom woven labels, hang tags, individual poly bags, branded boxes

1,000+ Units (Major Brand Partnership)

Pearl Weave 450 GSM: $38-48 per gi
Total Investment: $38,000-47,952
Production Time: 5-6 weeks
Best For: Major brands, national franchises, export businesses
Retail Potential: $120,000+ (at $120/gi retail)
Profit: $82,000-72,048+ (215-360% markup)
Perks: Dedicated production line, inventory management support, global logistics coordination

All prices include: Standard embroidery (3 placements), custom patches, professional packaging, quality inspection

Not included: International shipping (quoted separately), express production fees, premium add-ons

IBJJF Competition Legal Requirements

For gis intended for IBJJF tournament use, FitmanPro ensures compliance with official regulations:​

Color Regulations

Allowed Colors ONLY:

• White
• Royal Blue
• Black

Illegal Colors: Navy, grey, green, red, mixed colors will fail inspection

Color Consistency: Jacket, pants, and belt must match (white gi = white pants)

Measurement Specifications

Jacket Requirements:

• Length: Must reach mid-thigh minimum when standing
• Sleeves: Maximum 5cm from wrist when arm extended parallel to ground
• Sleeve opening: Minimum 7cm at wrist (prevents excessive tightness)
• Lapel thickness: 1.3cm standard
• Collar width: 5cm standard

Pants Requirements:

• Length: Maximum 5cm above ankle bone (tibial malleolus)
• Cannot drag on ground
• Waist must stay secure without belt

Fabric Requirements:

• Cotton or cotton-blend only
• Must be opaque (not see-through)
• No excessive stretching
• Strong enough to withstand competition stress

Logo/Patch Size Limits:

• Follow current IBJJF patch size regulations (check annually for updates)
• Generally: patches must not exceed specified dimensions on jacket/pants

FitmanPro IBJJF Compliance: Our design team verifies all competition gi orders meet current IBJJF specifications during mockup approval phase.

Worldwide Shipping From Pakistan

FitmanPro ships custom gi orders to 150+ countries:

North America Shipping

USA:

• Standard: 16-20 days ($250-500 for 50-unit order)
• Express (DHL): 8-12 days ($400-700)
• Popular Ports: Los Angeles, New York, Miami
• Customs: Usually $0-100 duty for sportswear

Canada:

• Standard: 18-22 days ($280-550)
• Express: 10-14 days ($450-800)
• Customs: 10-15% duty typical

Mexico:

• Standard: 20-24 days ($300-600)
• Express: 12-16 days ($500-900)

Europe Shipping

UK:

• Standard: 14-18 days ($280-550)
• Express: 7-10 days ($450-750)

Germany, France, Spain, Italy:

• Standard: 16-20 days ($300-600)
• Express: 8-12 days ($500-850)

Scandinavia (Sweden, Norway, Denmark):

• Standard: 18-22 days ($350-650)
• Express: 10-14 days ($550-950)

Australia/New Zealand

Australia:

• Standard: 18-24 days ($320-650)
• Express: 12-16 days ($550-1,000)

New Zealand:

• Standard: 20-26 days ($350-700)
• Express: 14-18 days ($600-1,100)

Asia-Pacific

UAE, Saudi Arabia:

• Standard: 10-14 days ($200-400)
• Express: 6-9 days ($350-600)

Singapore, Malaysia:

• Standard: 12-16 days ($220-450)
• Express: 7-11 days ($400-700)

Japan, South Korea:

• Standard: 14-18 days ($250-500)
• Express: 8-12 days ($450-800)

South America

Brazil:

• Standard: 22-28 days ($400-800)
• Express: 15-20 days ($700-1,200)
• Note: Brazilian customs can be complex; FitmanPro provides full documentation

Argentina, Chile:

• Standard: 20-26 days ($380-750)
• Express: 14-19 days ($650-1,100)

Shipping Notes:

• All prices FOB Pakistan (Free On Board – buyer pays shipping)
• Express shipping 40-60% faster, 50-80% more expensive
• Tracking provided for all shipments
• Insurance included up to order value
• Customs documentation provided (commercial invoice, packing list, origin certificate)

Quality Control & Production Standards

FitmanPro 10-Point Quality Inspection:

1. Fabric Verification

• GSM weight tested on every roll
• Shrinkage pre-testing (sample washed 3x before production)
• Colorfastness testing (ISO standards)
• Visual inspection for weave defects

2. Cutting Precision

• Computer-aided pattern cutting
• Size accuracy within 1cm tolerance
• Pattern consistency across all units

3. Stitching Quality

• Reinforced stress points (armpits, crotch, knees)
• Flatlock seams where required
• Thread tension standardized
• No loose threads or skipped stitches

4. Embroidery Accuracy

• Design matches approved mockup exactly
• Thread color verification
• Density check (professional appearance)
• Backing reinforcement

5. Patch Placement

• Measured placement (consistent across all gis)
• Secure attachment (won’t detach during training)
• Alignment verification

6. Assembly Inspection

• All components present (jacket, pants, drawstring, bag if included)
• Size labeling accuracy
• Care label attachment

7. Wash Testing

• Random samples washed 5 cycles
• Shrinkage measurement
• Color bleeding test
• Embroidery durability check

8. Size Accuracy

• Random measurement verification
• Jacket length, sleeve length, pant length checked
• Comparison to size chart specifications

9. Final Visual Inspection

• Each gi individually inspected
• Stain/defect check
• Overall appearance assessment

10. Photography Documentation

• Pre-shipment photos sent to client
• Approval before shipping initiated
• Packaging verification

Defect Rate: <0.3% (industry-leading standard)
Replacement Policy: Free replacement for manufacturing defects within 30 days of delivery
Quality Guarantee: 100% satisfaction or remake at no charge

Pricing Comparison: Pakistan vs Global Competition

Why Pakistan Dominates Custom Gi Manufacturing:

Cost Advantage:

• 45-60% lower than USA/Japan
• 15-25% lower than China
• 30-40% lower than Brazil

Sialkot Manufacturing Legacy:

• 60+ years combat sports equipment expertise
• Largest martial arts manufacturing hub globally
• Specialized BJJ gi factories (not general textiles)
• Fourth-generation craftsmen

Communication Excellence:

• English-speaking design teams
• WhatsApp/Email/Video call support
• Time zone compatibility (can accommodate US/Europe schedules)
• Dedicated account managers for 100+ unit orders

Speed & Reliability:

• Faster than China (less bureaucracy)
• Faster than USA (lower production volume = quicker turnaround)
• Reliable delivery timelines (95% on-time rate)

Quality Parity:

• Same fabric sources as premium Western brands
• ISO-certified production facilities
• International quality standards
• Many Western brands manufacture in Pakistan (private label)

Case Studies: Successful Custom Gi Programs

Case Study 1: Mid-Size BJJ Academy (120 Students)

Program Details:

• Order: 80 custom gis (pearl weave 450 GSM, white with academy logo)
• Cost: $4,640 ($58/gi including shipping)
• Retail Price: $140/gi to students
• Sales Timeline: 3 months
• Units Sold: 68 gis (85% sell-through)

Results:

• Revenue: $9,520
• Profit: $4,880 (105% markup)
• Bonus: 12 extra gis kept for loaner/trial program

Academy Owner Testimonial:

“Custom gis transformed our academy culture. Students wear them proudly, retention increased, and we generated almost $5,000 profit while building team identity.”

Case Study 2: Competition Team (40 Athletes)

Program Details:

• Order: 50 gis (40 for team, 10 retail stock)
• Mix: 30 blue gis, 20 white gis (competition variety)
• Cost: $3,000 ($60/gi pearl weave with team patches)
• Strategy: Required gear for competition team members

Results:

• Team equipped at wholesale cost
• Retail sales: 9/10 extra gis sold at $150 each = $1,350 revenue
• Net cost for team: $1,650 ($41.25/athlete)
• Sponsorship: Sponsor logos on gi secured $8,000 annual deal

Team Captain Quote:

“Unified appearance at IBJJF tournaments made us look professional. Sponsors noticed immediately. The gis paid for themselves through sponsorship alone.”

Case Study 3: Emerging BJJ Brand (Private Label)

Program Details:

• Order: 200 gis (mixed sizes, white label)
• Cost: $10,400 ($52/gi pearl weave with custom branding)
• Sales Channel: Online store + Instagram marketing
• Retail Price: $159.99/gi

Results (6 Months):

• Units Sold: 147 gis (73.5% sell-through)
• Revenue: $23,519
• Profit: $13,119 (126% markup)
• Remaining Inventory: 53 gis ($8,480 value at retail)

Brand Owner:

“FitmanPro’s white label service let us launch our brand with minimal investment. Quality rivals $200+ gis. Customers love them.”

Case Study 4: Franchise Network (5 Locations, 600 Students)

Program Details:

• Order: 350 gis (70 per location, mixed sizes)
• Cost: $18,900 ($54/gi volume discount)
• Retail Price: $135/gi
• Strategy: Required gi for all students (uniform policy)

Results (12 Months):

• Units Sold: 312 gis (89% sell-through)
• Revenue: $42,120
• Profit: $23,220 (123% markup)
• Ongoing: Reorder of 200 gis every 6 months

Franchise Owner:

“Custom gis created brand consistency across all locations. Students recognize our academy anywhere. This generates $40K+ annually while maintaining professional standards.”

How to Order Custom Gis From FitmanPro

Step-by-Step Process:

Day 1-2: Initial Contact & Consultation

Contact Methods:

• Website: fitmanpro.com (contact form)
• Instagram: @fitman.pro (DM for quick response)
• Email: [provide email address]
• WhatsApp: [provide number] (fastest for international clients)

Information to Provide:

• Academy/team/brand name
• Desired quantity (approximate)
• Logo files (PDF, AI, or high-res PNG)
• Preferred colors (white/blue/black for IBJJF)
• Size breakdown estimate
• Timeline requirements
• Any special customization requests

Day 3-5: Design Mockup & Revision

What You’ll Receive:

• 3D mockup showing exact gi appearance
• Embroidery placement preview
• Size chart recommendation
• Detailed quote breakdown
• Production timeline

Revision Process:

• Request unlimited design changes
• Adjust logo sizes, placement, colors
• Modify patches, add/remove elements
• Final approval required before production

Day 6-7: Quote Approval & Payment

Quote Includes:

• Unit price (based on quantity)
• Customization costs (embroidery, patches)
• Packaging options
• Shipping estimate (to your country)
• Total investment required

Payment Terms:

• 50% deposit to begin production
• 50% balance before shipping
• Payment methods: PayPal (buyer protection), Wire Transfer, Western Union

What Happens After Payment:

• Production slot reserved
• Fabric ordered (if not in stock)
• Embroidery digitization begins

Day 8-28: Production Phase (2-3 Weeks)

Production Timeline:

• Week 1: Fabric cutting, initial assembly
• Week 2: Embroidery, patch attachment, assembly completion
• Week 3: Quality control, packaging, pre-shipment inspection

Updates Provided:

• Progress photos every 5-7 days
• Video updates for large orders (200+ units)
• Direct communication with production manager

Pre-Shipment Approval:

• Detailed photos of completed gis sent
• Size samples measured and documented
• Packaging shown
• Client approval required before shipping

Day 29-35: Shipping & Customs

Shipping Process:

• Tracking number provided
• Estimated delivery date
• Customs documentation included (commercial invoice, packing list, origin certificate)
• Insurance included up to order value

Customs Clearance Support:

• FitmanPro provides all required documentation
• Assistance with customs queries
• Typical clearance: 1-3 days in most countries

Day 36-50: Delivery & Quality Check

Upon Delivery:

• Inspect shipment immediately
• Verify unit count
• Check for any shipping damage
• Quality assessment (stitching, embroidery, sizing)

Issue Resolution:

• Report defects within 48 hours
• Photo documentation required
• Replacement gis produced and shipped free of charge (rare – <0.3% defect rate)

Total Timeline: 36-50 days from initial contact to delivery (Standard shipping)
Express Timeline: 25-35 days (Express production + shipping)

Design Best Practices for Maximum Impact

Logo Design Principles

Chest Logo (Primary Placement):

• Optimal Size: 4″x4″ to 6″x6″
• Placement: Center chest, 2-3 inches below collar
• Visibility: Highest during standing, photo opportunities
• Design Tip: Keep simple for this size (intricate details lost)

Back Logo (Secondary Branding):

• Optimal Size: 10″x12″ to 12″x14″
• Placement: Upper back between shoulder blades
• Visibility: Dominant in training, competition podium photos
• Design Tip: Can include detailed graphics, text, sponsor collage

Shoulder Patches:

• Optimal Size: 3″x3″ to 4″x4″ per shoulder
• Common Use: Country flags, belt rank indicators, sponsor logos
• Design Tip: Symmetrical placement for professional look

Sleeve Patches:

• Optimal Size: 2″x2″ to 3″x3″
• Placement: Outer bicep area
• Common Use: Secondary sponsors, affiliate programs
• Design Tip: Limit to 1-2 per arm (avoid clutter)

Lapel Embroidery:

• Text Only: Academy name or athlete name
• Size: Small text, professional embroidery thread
• Visibility: Close-up photos, referee inspection

Pant Leg Embroidery:

• Placement: Vertical down left or right thigh
• Content: Academy name, athlete name, motto
• Size: 1-2 inch tall letters

Color Psychology & Branding

White Gis (60% of Academy Orders):

• Perception: Clean, traditional, professional
• Best Accent Colors: Black, navy, royal blue, gold
• Competition: Shows discipline (visible dirt encourages cleanliness)
• Embroidery Visibility: All colors stand out well

Blue Gis (30% of Orders):

• Perception: Modern, vibrant, team-oriented
• Best Accent Colors: White, gold, yellow, silver
• Competition: IBJJF-legal, hides sweat stains
• Embroidery Visibility: Light colors (white, gold) pop; dark colors blend

Black Gis (10% of Orders):

• Perception: Aggressive, elite, modern aesthetic
• Best Accent Colors: White, red, gold, silver
• Competition: IBJJF-legal, hides all stains
• Embroidery Visibility: Light colors only (white, gold, silver)

Sponsor Integration Strategy

4-Sponsor Layout (Most Professional):

1. Primary Sponsor: Back (large – 10″x10″)
2. Secondary Sponsor: Right shoulder (4″x4″)
3. Tertiary Sponsor: Left shoulder (4″x4″)
4. Quaternary Sponsor: Left sleeve (3″x3″)

6-Sponsor Maximum (Before Looking Cluttered):

• Add: Right sleeve, pant leg placements
• Maintain size hierarchy (largest sponsor gets most prominent placement)

Sponsorship Revenue Guide:

• Back placement: $2,000-5,000/year (most visible)
• Shoulder placement: $1,000-2,500/year each
• Sleeve placement: $500-1,500/year each

Maintenance & Care for Longevity

Washing Instructions (Extend 450 GSM Gi to 1,200+ Hours):

Pre-Wash Preparation

First Wash (New Gi):

• Wash alone in cold water (prevents dye transfer)
• Expect 2-4% shrinkage (plan sizing accordingly)
• Air dry completely before first use
• Complete gi washing guide

After Every Training:

• Wash within 6 hours (prevents bacterial growth, staph/ringworm prevention)
• Never leave wet in gym bag

Washing Process

Water Temperature:

• Cold water ONLY (hot water destroys fabric integrity)
• Warm water = accelerated shrinkage + color fading

Detergent:

• Sport-specific or mild detergent
• Avoid fabric softener (clogs pores, reduces moisture-wicking)
• White vinegar (1/4 cup) helps remove odors, set colors

Machine Settings:

• Gentle/delicate cycle (reduces stress on embroidery)
• Normal cycle acceptable if not heavily soiled
• Turn gi inside-out (protects embroidery from abrasion)

What NOT to Do:

• No bleach (weakens fibers, yellows white gis)
• No fabric softener
• Don’t overload machine (gi needs space to agitate)

Drying

Air Dry (Best for Longevity):

• Hang on padded hanger or lay flat
• Avoid direct sunlight (UV fades colors)
• Well-ventilated area (prevents mildew)
• Drying time: 12-24 hours depending on climate

Machine Dry (Not Recommended, But If Necessary):

• Low heat ONLY
• Remove while still slightly damp
• High heat = significant shrinkage + fabric damage
• Reduces gi lifespan by 30-40%

Stain Removal

Blood Stains:

• Rinse immediately in cold water
• Hydrogen peroxide application (before wash)
• Never hot water (sets blood stains permanently)

Mat Grime/Dirt:

• Pre-soak in cold water 30 minutes
• Sport stain remover on affected areas
• Normal wash cycle

Stubborn Stains:

• OxiClean soak (oxygen-based, safe for colors)
• 2-4 hour soak before washing
• No chlorine bleach (damages fabric)

Storage

Between Training Sessions:

• Hang in cool, dry place (closet, gear room)
• Never store damp (mildew grows in 24-48 hours)
• Separate from street clothes (cross-contamination)

Long-Term Storage:

• Clean and completely dry
• Fold or hang in breathable garment bag
• Cedar blocks (natural moth/odor prevention)
• Climate-controlled area (avoid attics, basements with humidity)

Repair & Maintenance

Minor Repairs:

• Loose threads: Trim with scissors (don’t pull)
• Small tears: Hand-stitch with heavy thread immediately (prevents expansion)
• Drawstring replacement: Simple DIY with paracord or new drawstring

Embroidery Maintenance:

• Avoid rubbing embroidered areas against rough surfaces
• Check backing periodically (if fraying, reinforce with hand-stitching)
• Professional repair if significant damage

When to Retire a Gi:

• Visible thinning/see-through fabric
• Large tears in high-stress areas (armpits, crotch)
• Collar/lapel damage affecting grip strength
• After 1,200-1,500 training hours (pearl weave 450 GSM typical lifespan)

Frequently Asked Questions

Q: What’s the minimum order for fully custom gis?
A: 25 units. This is industry-low for premium custom manufacturing. Most competitors require 50-100 minimum.

Q: Can I order mixed sizes in one order?
A: Yes. Provide size breakdown (e.g., 10 A1, 15 A2, 20 A3, 5 A4) and FitmanPro produces exact quantities.

Q: How long does custom embroidery last?
A: Permanent. High-quality embroidery survives the entire gi lifespan (1,000-1,500+ hours) with proper care.

Q: Are FitmanPro gis IBJJF competition legal?
A: Yes, when designed to specifications. FitmanPro’s team ensures compliance during design phase for white, blue, and black gis with proper measurements.

Q: Can I get samples before bulk order?
A: Yes. Sample gis available at $75-95 each including shipping. Sample cost credited toward bulk order (50+ units) if placed within 90 days.

Q: What if my academy grows and I need more gis later?
A: Designs stored for 2 years. Reorders processed at current pricing with faster turnaround (no design phase needed).

Q: Do you offer kids sizes?
A: Yes. M000-M4 (ages 3-16). Same customization options as adult gis.

Q: Can individual athlete names be added?
A: Yes. Roster embroidery available (+$8-12/gi). Provide name list with size breakdown.

Q: What’s the difference between pre-shrunk and regular?
A: Pre-shrunk undergoes controlled shrinking during manufacturing (2-3% additional shrink). Regular shrinks 3-5% after first wash. Pre-shrunk costs +$3-5/gi.

Q: How do I choose between pearl, gold, and single weave?
A: Pearl weave (450 GSM) recommended for 90% of academies – best balance of durability, weight, price. Gold weave if premium feel desired. Single weave only for extreme budget constraints.

Q: Can you match our existing gi design?
A: Yes. Send photos of current gis and FitmanPro replicates design (intellectual property permitting).

Q: What payment methods protect international buyers?
A: PayPal offers buyer protection. Wire transfer recommended for orders $5,000+ (lower fees). 50% deposit protects both parties.

Q: What happens if sizing is wrong?
A: Size accuracy guaranteed within 1cm per size chart. If manufacturer error, free remake. If client error (wrong size chart), remake at cost.

Q: Can we add QR codes or special tags?
A: Yes. Custom woven labels, hang tags with QR codes, care instruction tags all available (100+ unit orders).

Why Choose FitmanPro for Custom BJJ Gis

Manufacturing Excellence

60+ Years Sialkot Legacy:

• Fourth-generation martial arts equipment craftsmen
• Largest combat sports manufacturing hub globally
• Specialized BJJ gi production (not generic garment factory)
• 15+ years exclusive BJJ gi experience

Quality Standards:

• ISO 9001:2015 certified facility
• International quality control protocols
• <0.3% defect rate (industry-leading)
• Premium fabric sourcing (same suppliers as $200+ Western brands)

Customer-Centric Service

Design Support:

• Free unlimited mockup revisions
• Professional design consultation included
• 24-48 hour mockup turnaround
• 3D rendering preview technology

Communication:

• English-fluent design and customer service teams
• WhatsApp, email, video call support
• Time zone flexibility (accommodate US/Europe schedules)
• Dedicated account managers (100+ unit orders)

Transparency:

• No hidden fees (all costs quoted upfront)
• Progress updates throughout production
• Pre-shipment photo approval
• Tracking from factory to delivery

Competitive Advantages

Pricing:

• 45-60% lower than USA/Japan manufacturing
• 15-25% lower than China
• Volume discounts (best rates at 250+ units)
• No setup fees, no design charges

Speed:

• 2-3 week standard production (faster than industry average)
• Rush production available (1-2 weeks)
• Express shipping options worldwide
• 95% on-time delivery rate

Flexibility:

• Lowest MOQ in industry (25 units for premium custom)
• Mixed size orders accepted
• Reorder support (designs stored 2 years)
• Custom sizing for large orders (100+ units)

Global Reach

150+ Countries Served:

• Clients in North America, Europe, Australia, Asia, Middle East, South America
• Complete customs documentation
• International shipping expertise
• Local import regulation knowledge

Proven Track Record:

• 5,000+ custom gi orders completed
• Partnerships with professional fighters, national teams, academies worldwide
• White label manufacturing for established BJJ brands
• 98% customer satisfaction rate

Related Resources

• What is BJJ? – Complete introduction for beginners
• How to Choose a BJJ Gi – Buying guide for individuals
• How to Wash BJJ Gi – Care and maintenance
• BJJ Belt System Guide – Rank progression
• Custom BJJ Rash Guards – No-gi custom apparel
• What is IBJJF? – Competition organization and rules
• Gi vs No-Gi Training – Style comparison
• Prevent Ringworm & Staph – Hygiene importance
• BJJ Hygiene Tips – Training cleanliness
• Top BJJ Gyms in New York – Academies using custom gear
• Starting BJJ at 30 – Adult beginner guide
• First BJJ Class Guide – What to expect
• Does BJJ Make You Stronger? – Fitness benefits
• BJJ White Belt Guide – Beginner progression
• 30 White Belt Tips – Beginner advice

Custom BJJ Gis – Transform your academy into a professional brand, generate substantial retail revenue ($20,000-60,000+ annually), and equip your team with premium competition-grade kimonos manufactured by Pakistan’s leading combat sports factory with 60+ years Sialkot craftsmanship legacy serving 150+ countries worldwide.

Get your free design mockup today: Contact FitmanPro