Custom BJJ Gi for Teams: Fabric, MOQ & Design Guide

Get a custom gi quote for your academy within 24 hours

BJJ Sportswear manufactures custom gis for academies worldwide. Pearl weave, gold weave, and ripstop options. IBJJF compliant. Adult and youth sizing available.export@fitmanpro.com →

Include: number of units needed, size breakdown, gi colour, and your logo file if ready.

The custom gi is the most powerful statement a BJJ academy can make.

When your entire competition team walks into a venue in matching, branded gis — with your logo on the chest, your academy name on the back, your colours consistent from white belt to black — it signals a professional, unified programme. New students notice. Parents notice. Other gyms notice.

It is also the most complex and expensive custom gear order you will place. A rash guard order is relatively forgiving. A gi order — with its fabric weight choices, weave types, IBJJF compliance requirements, shrinkage considerations, and longer lead times — requires proper preparation to get right.

This guide gives you everything you need to order with confidence. No vague supplier promises. No surprises on delivery day.

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Why the gi is the highest-value academy gear investment

The gi is worn for the majority of training hours in most BJJ academies. It is seen at every gi class, at every competition, at belt promotions, and in every photo and video your academy produces. No other piece of gear gets more visibility.

There is also a practical argument. Students typically buy one or two gis and use them for years. A custom academy gi purchased by your student stays in rotation for two to four years of daily training. That is two to four years of your logo on the mat, at tournaments, and in the wider BJJ community.

For the business case, see the full breakdown in our custom BJJ team gear cost guide — which covers gis, rash guards, and shorts side by side with ROI analysis for gym owners.

The retention argument is real too. Students who own their academy’s official gi feel a stronger sense of belonging. They are more likely to represent your gym at competitions, refer friends, and stay long term. Custom gear is not just a uniform — it is a retention tool.

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Weave types explained

The weave is the single biggest quality differentiator in a BJJ gi. It determines weight, durability, how the gi moves during rolling, and how it handles regular washing. Understanding the options saves you from ordering the wrong product.

Pearl weave — the standard choice

Pearl weave is the most widely used weave in modern BJJ competition gis. The fabric has a distinctive pearl-like texture — small, round bumps across the surface. This texture reduces gripping surface slightly (making it harder for opponents to hold), while maintaining excellent durability. Pearl weave gis are lighter than gold weave, making them more comfortable in warm training environments. For most academies, pearl weave is the right choice.

Gold weave — the durable classic

Gold weave is heavier and denser than pearl weave. It has been used in BJJ since the early days of the sport. Gold weave gis are extremely durable — they last longer under daily hard training — but they are warmer and heavier to wear. Less common in modern competition gis, but popular with practitioners who prioritise longevity over weight.

Single weave — the lightweight budget option

Single weave is the lightest and cheapest option. It is significantly less durable than pearl or gold weave and breaks down faster under daily training. Suitable as a beginner or starter gi but not recommended as your academy’s primary custom gi — students who train regularly will go through single weave gis much faster.

Double weave — the heaviest option

Double weave is extremely dense and heavy. It is very durable but uncomfortable in anything but cold training environments. Rarely used for modern competition gis. Not recommended for a standard academy order.

Ripstop pants fabric

Ripstop is a fabric weaving technique — not a gi jacket weave type — used primarily for gi pants. Ripstop fabric has a distinctive crosshatch pattern and is extremely tear-resistant. Most quality custom gis pair a pearl weave jacket with ripstop pants. This is the ideal combination for daily training durability.

Weave	Weight	Durability	Best for	Recommendation
Pearl weave	Medium	High	Competition + daily training	✅ Best for most academies
Gold weave	Heavy	Very high	Heavy training environments	Good secondary option
Single weave	Light	Low	Beginner/starter gis only	Not recommended for custom orders
Double weave	Very heavy	Excellent	Cold climate academies	Specialist use only
Ripstop (pants)	Light	Very high	Gi pants fabric	✅ Standard for pants

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GSM — fabric weight guide

GSM stands for grams per square metre — the standard measure of fabric weight. The higher the GSM, the heavier and typically more durable the fabric.

For BJJ gi jackets, GSM typically ranges from 350 to 550. Here is how to choose:

GSM range	Feel	Best for
350 – 400 GSM	Lightweight, minimal	Competition-focused academies, warm climates, lighter gi preference
420 – 480 GSM	Medium — the sweet spot	Most academies. Balances durability with comfort. IBJJF competition standard.
500 – 550 GSM	Heavy, very durable	Academies with heavy training culture, cooler climates, maximum longevity priority

Recommendation: For a standard custom academy gi order, specify 450 GSM jacket with ripstop pants. This is the most widely used specification in professional academy gear orders worldwide and meets IBJJF competition requirements.

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Gi colours and IBJJF compliance

If your students compete in IBJJF events, the colour of your custom gi is not optional — it must comply with IBJJF rules.

IBJJF approved colours	Notes
White	Most common. Works for all belt levels. Easy to match across different manufacturers.
Royal blue	IBJJF standard blue. Must be royal blue — not navy, not light blue. Specify “IBJJF royal blue” to your supplier.
Black	Permitted at all belt levels. Popular with academies wanting a professional, sharp look.
Any other colour	Not permitted in IBJJF competition. Fine for training-only gis.

For academies whose students compete under IBJJF rules, the practical approach is to order in white, royal blue, or black — and keep your customisation (logo, academy name, patches) within IBJJF patch size and placement limits.

IBJJF patch placement rules as of 2026:

• Patches on the gi jacket must be stitched down on all four sides
• No patch may exceed a defined maximum size (refer to current IBJJF rulebook for exact dimensions — rules are updated periodically)
• Patches and branding may not cover the IBJJF official patches when used
• The gi colour must be solid and consistent — no two-tone jackets unless the contrast panel is within approved guidelines

Important: IBJJF rules are updated periodically. Always download the current IBJJF rulebook before finalising your gi design for competition use. Confirming compliance with your supplier is not sufficient — confirm directly against the current rulebook.

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Embroidery vs sublimation — which to choose for your gi

This is the most important design decision for a custom gi order. Embroidery and sublimation are not interchangeable — each has specific strengths and limitations on a gi.

Embroidery

Embroidery stitches your design directly into the gi fabric using thread. The result looks premium, feels professional, and lasts the entire life of the gi without fading or cracking. Embroidery handles best with logos and text that have clear, defined edges and a limited number of colours. It is the traditional and most respected customisation method for BJJ gis.

Best for: Academy logo on the left chest, academy name on the back collar, belt rank patches, and sleeve text.

Limitations: Cannot reproduce complex gradients or photographic images. More expensive per placement than printing. Colour options are limited to thread colours — typically 15 to 20 available per supplier.

Sublimation (on panels or patches)

Full sublimation printing directly onto the gi jacket fabric is not possible on cotton or heavy cotton-blend gi material — sublimation requires polyester. However, sublimation is used extensively for gi patches, collar linings, and sleeve panels made from polyester fabric that are then stitched onto the gi.

Best for: Complex multi-colour logos, sleeve panels with gradient designs, patch art with photographic elements, inside collar branding.

Limitations: Sublimated patches look different from the gi fabric itself — there is a visible transition between the gi material and the patch. This can look very sharp with good design, but requires careful design planning.

What most academies do

The most professional result combines both methods: embroidery for the main logo (left chest) and academy name (back collar or back panel), and sublimated patches for sleeve graphics, back panel art, or collar lining branding. This approach uses each method where it performs best.

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Logo and patch placement options

Understanding where customisation can go on a gi prevents expensive surprises. Here are the standard placement options:

Placement	Method	Visibility	IBJJF impact
Left chest (jacket)	Embroidery or patch	Very high	Check current size limits
Right chest (jacket)	Embroidery or patch	High	Check current size limits
Back collar (jacket)	Embroidery or woven label	Medium — seen from behind	Generally permitted
Upper back (jacket)	Embroidery or large patch	Very high — seen during rolling	Check current size limits
Sleeve (jacket)	Embroidery or sublimated panel	High — seen during gripping	Check current rules
Left hip (pants)	Embroidery or patch	Medium	Generally permitted
Knee (pants)	Ripstop panel with sublimation	Medium	Generally permitted
Inside collar lining	Sublimated fabric lining	Low — hidden normally	No IBJJF restrictions

For a first custom gi order, a practical starting point is: left chest embroidery (main logo) + back collar embroidery (academy name) + left sleeve embroidery (founding year or motto). This creates a clean, professional look without overloading the gi with branding.

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Cost breakdown by order size — 2026

These are estimated per-unit manufacturing costs for a custom pearl weave gi (450 GSM jacket + ripstop pants) with embroidered logo on chest and back. Actual pricing varies by supplier, fabric choice, and number of embroidery placements.

Order size	Estimated cost per gi	Notes
10 – 19 units	$95 – $130	Small team or sample order. Premium pricing. Useful for quality testing a new supplier.
20 – 30 units	$75 – $100	Small academy first gi order. Common starting point.
31 – 50 units	$60 – $80	Mid-size academy. Good price-quality balance.
51 – 100 units	$50 – $68	Larger academy or annual blanket order.
100+ units	$45 – $58	Multi-location gym or annual academy-wide order. Best per-unit pricing.

Each additional embroidery placement (sleeve, back panel, pants) typically adds $2 to $8 per unit depending on the size and complexity of the design.

Shipping costs for gis are significantly higher than rash guards due to weight and volume. Budget 15 to 25% of the order value for international shipping on gi orders, depending on your location.

For a complete side-by-side cost comparison of gis versus rash guards versus shorts for academy orders, see the custom BJJ team gear cost breakdown.

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Minimum order quantities for custom gis

Custom gi orders have higher minimum order quantities than rash guards because gi manufacturing involves significantly more production steps — cutting, sewing, weaving, multiple component assembly, and finishing.

Typical MOQs from quality suppliers:

• 10 to 19 units: Available from some suppliers at premium pricing. Good for a first small order to test quality before committing to a larger run.
• 20 to 30 units: The standard minimum for most quality custom gi manufacturers. This is where per-unit pricing becomes commercially viable for most academies.
• 50+ units: Required by some larger manufacturers for bulk pricing. Best for established academies with a full student roster.

BJJ Sportswear handles custom gi orders from 20 units upward. Email export@fitmanpro.com with your size run and colour preference for a quote within 24 hours.

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Design requirements — what to prepare before ordering

The most common cause of gi order delays is incomplete design preparation. Prepare all of the following before making contact with your supplier.

Logo file

You need a vector file (AI, EPS, or SVG). For embroidery specifically, your supplier will convert this to an embroidery digitisation file — but they need a clean vector to start from. A blurry JPEG logo will produce blurry embroidery. If you only have a JPEG, ensure it is at minimum 300 DPI and ask your supplier whether they can work from it.

Colour choices

Specify the gi base colour (white, royal blue, or black for IBJJF compliance). For embroidery thread colours, provide Pantone codes if available. If not, provide a reference image and your supplier will colour-match. Most embroidery suppliers have 15 to 20 standard thread colours — confirm your logo colours can be matched before committing.

Placement decisions

Decide before the design call: which placements you want (chest, back collar, sleeve, pants), which method for each (embroidery or patch), and approximate size of each placement. Your supplier will propose exact sizes in the mockup — but having clear intent speeds the process significantly.

Size run

Know your full size run before ordering. BJJ gis use a specific sizing system (A0 through A6 for adults, M0 through M4 for juniors) that differs from standard clothing sizes. Ask your supplier for their size chart and map each student to a size before finalising numbers. See the sizing section below for more guidance.

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Pre-shrunk fabric — why it matters

Cotton-based BJJ gi fabric shrinks when washed — particularly in hot water. This is one of the most common sources of student dissatisfaction after a custom gi order.

Quality gi manufacturers pre-shrink the fabric before cutting and sewing. This means the gi you receive is already at its post-wash dimensions — washing will not significantly change the fit. Ask your supplier explicitly: “Is the fabric pre-shrunk before production?”

If the fabric is not pre-shrunk, the gi your student receives may shrink by one to two size grades after the first few washes. A student fitted in an A2 may find themselves in a tight A1 after three washes. This is an expensive problem on a bulk order.

BJJ Sportswear uses pre-shrunk fabric on all custom gi orders as standard. This is non-negotiable for a professional academy gear supplier.

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Gi pants — fabric, cut, and drawstring

The pants are often an afterthought in gi design — but they account for approximately half of all student complaints about gi quality. Get the pants specification right.

Fabric

Ripstop is the standard for quality gi pants. The crosshatch weave pattern prevents tears from spreading — a common failure point in cheaper cotton drill pants. Specify ripstop pants explicitly if your supplier offers a choice.

Cut

Gi pants come in two cuts: traditional (wider leg opening, more room in the thigh) and tapered (slimmer leg opening, more athletic fit). Modern competition gis typically use a tapered cut. For an academy-wide order with students of varying body types, a mid-weight traditional cut tends to fit the broadest range of body shapes without custom tailoring.

Drawstring vs elastic

Competition-legal gi pants must use a rope drawstring at the waist — not a wide elastic waistband. IBJJF requires a rope-style drawstring. Confirm your pants use a cotton rope drawstring, not elastic only, if your students compete under IBJJF rules.

Knee reinforcement

Quality custom gis include double-layer knee panels on the pants. The knee is the highest-stress area in BJJ pants — knee-on-belly, kneeling, and guard recovery all concentrate wear at this point. Single-layer knee panels on gi pants are a common cost-cutting measure that leads to faster degradation. Ask your supplier whether the pants include reinforced knee panels.

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Lead times — realistic planning guide

Custom gi orders take significantly longer than rash guard orders. Every gym owner who has rushed a gi order has regretted it. Plan early.

Stage	Realistic time	Notes
Initial quote and consultation	1 to 3 days	Faster with logo file and size run ready
Embroidery digitisation	3 to 7 days	Converting your logo to embroidery file format
Design mockup	5 to 10 days	Visual mockup of your gi with placements shown
Sample production (recommended)	10 to 21 days	Physical sample gi for fit and quality approval
Your approval	3 to 7 days	The most variable stage — depends on your team’s review speed
Bulk production	28 to 45 days	Longer for larger orders and during peak season
Quality inspection and packing	3 to 7 days	Per-unit inspection essential — do not skip suppliers who do this
International shipping	7 to 21 days	Air freight faster, sea freight cheaper for 100+ units
Total realistic timeline	10 to 16 weeks	Always add 3 weeks buffer. Plan for 12 weeks minimum.

Competition planning rule: If you want your academy in custom gis for a specific event, start the order process 16 weeks (4 months) before the event. This gives you full buffer for sample approval, production delays, and shipping variation.

Sizing for a mixed academy roster

BJJ gi sizing is not intuitive — it uses a dedicated system that does not map directly to standard clothing sizes. Getting this right on a bulk order is critical.

Adult sizing

Standard BJJ gi sizes for adults are A0 through A6. The A designates “Adult” — the number indicates the size tier. A1 to A3 cover most adult practitioners. A0 is for very lightweight/short adults. A4 to A6 cover larger builds. Some manufacturers also offer short (S), regular, and long (L) variations within each size tier (e.g. A2S for a shorter-built A2 practitioner).

Junior / youth sizing

Youth and junior sizes are designated M0 through M4 (M for “Minor”). M0 to M1 fits younger children, M3 to M4 fits older teenagers. If your academy has a kids programme, confirm your supplier stocks the full junior size range before ordering.

Getting measurements right

Do not rely on what students say their gi size is. Different manufacturers size differently — an A2 from one brand may fit very differently from an A2 from another. Ask your supplier for their specific size chart (with height, weight, and chest circumference guidance) and measure each student against it. This one step prevents the majority of post-delivery sizing complaints.

Order a sample first

For orders of 30+ units, request a production sample in A2 (the most common adult size) before committing to full production. Fit the sample on several students of different body types. Confirm the pre-shrunk sizing holds after one wash. This is the single most important quality step for a gi order and is standard practice for experienced academy owners.

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Running a pre-order from your students

One of the most effective approaches to a first custom gi order is to run a pre-order from your student base. Instead of guessing how many of each size to order, you collect orders and payment from students first, then place a single bulk order with accurate numbers.

How to run a successful pre-order:

1. Design the gi first — have mockups ready to show students what they are ordering
2. Set a clear order deadline (2 to 3 weeks for collection)
3. Collect payment in advance — this covers your upfront manufacturing cost
4. Provide students with your supplier’s size chart and have them measure themselves properly
5. Place the confirmed bulk order once the pre-order window closes
6. Communicate the expected delivery timeline clearly — under-promise and over-deliver

Most academies add a 15 to 25% retail markup on the manufacturing cost when selling to students. This covers shipping, handling, sizing error replacements, and a small margin toward the next order cycle.

5 questions to ask any supplier before committing

1. “Is the fabric pre-shrunk before production?” The only acceptable answer is yes. If they cannot confirm pre-shrinking, expect sizing complaints after the first wash.
2. “What is the exact GSM and weave of the jacket, and what material are the pants?” Expect specific answers — 450 GSM pearl weave jacket with ripstop pants. Vague answers are a quality red flag.
3. “Can you provide a physical sample before bulk production?” Any professional custom gi manufacturer offers samples. If they refuse or charge excessively for samples on a 30+ unit order, reconsider.
4. “What is your quality control process and what happens if a gi has a defect on delivery?” Get the defect replacement policy in writing before ordering.
5. “Can you supply references from other BJJ academies you have made custom gis for?” An experienced supplier should have academy clients willing to provide a reference or testimonial.

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Pre-order checklist

• Logo vector file ready (AI, EPS, or SVG format)
• Gi colour decided — white, royal blue, or black for IBJJF compliance
• Weave type confirmed — pearl weave + ripstop pants recommended
• GSM specified — 450 GSM recommended for most academies
• Embroidery placements decided (chest, back collar, sleeve, pants)
• Thread colours confirmed against supplier’s colour chart
• IBJJF patch size and placement rules checked if students compete
• Accurate size run prepared — students measured against supplier’s size chart
• Pre-order window run with students OR surplus stock budget allocated
• Sample requested for orders of 30+ units
• Delivery deadline confirmed — order placed minimum 12 weeks before it
• Retail pricing to students decided if running a pre-order
• Defect replacement policy confirmed in writing

Common mistakes to avoid

• Not requesting a pre-shrunk fabric confirmation — most sizing complaints come from this
• Relying on students’ self-reported sizes instead of measuring against the specific size chart
• Not ordering a sample before bulk production for large orders
• Ordering non-IBJJF colours without confirming students do not compete under IBJJF rules
• Starting the order less than 12 weeks before a competition or event deadline
• Not getting the defect policy in writing before placing the order

Frequently asked questions

Ready to order your academy’s custom gi?

BJJ Sportswear manufactures custom gis for academies worldwide. Pearl weave and gold weave options. IBJJF compliant. Adult and youth sizing. Full embroidery and sublimation capabilities. Minimum 20 units.export@fitmanpro.com →

Include: number of units, size breakdown, gi colour, and logo file if ready. We respond within 24 hours on business days.

For the complete picture on academy gear costs including rash guards, shorts, and full kit pricing, see our custom BJJ team gear cost guide. For rash guard ordering specifically, see our custom rash guard guide for academies.