Custom Muay Thai Shorts: Manufacturing & Design Guide (2026)

Custom Muay Thai Shorts: Manufacturing & Design Guide (2026)

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

Custom Muay Thai shorts are premium fight gear designed specifically for kickboxing and traditional Thai boxing. Gyms, professional fighters, and brands order 50-500+ units at $20-36 per short. The price depends on fabric type (satin, polyester, microfiber), inseam length (10-14 inches), and customization features. These features include full sublimation printing, traditional embroidery, wide side slits, and elastic waistband customization. Pakistan-based manufacturers like FitmanPro in Sialkot offer authentic Muay Thai short construction. They use premium satin or polyester-spandex blend fabrics. FitmanPro ships to 150+ countries worldwide. Their customers include Muay Thai fighters, kickboxers, traditional Thai boxing gyms, and martial arts academies. Academies can make 40-65% retail markup on custom Muay Thai shorts.

Why Custom Muay Thai Shorts Drive Revenue & Brand Identity

Traditional Design Meets Modern Customization

Muay Thai shorts serve the dedicated striking and kickboxing market. According to Hayabusa Fight research, these shorts feature unique design elements. They have shorter length (10-14 inches inseam) for maximum leg mobility. Wide leg openings allow unrestricted high kicks and knee strikes. Traditional elastic waistband provides comfort during clinch work. These design features differ from MMA shorts which are longer and tighter. Muay Thai shorts focus purely on striking mobility. Custom-branded shorts generate $6,000-20,000 annually for kickboxing gyms with 80-150 members. Gyms buy them wholesale at $20-36 per short. Then they sell them retail at $50-75 per short. This creates 150-210% markup. The shorts also create unified team appearance during competitions and showcases.

Fighter Pride & Cultural Heritage

Custom Muay Thai shorts worn by fighters during traditional Muay Thai competitions, ONE Championship events, and kickboxing tournaments generate powerful cultural connection. Traditional Thai designs with custom gym logos merge heritage with modern branding. Fighters wearing custom shorts during Wai Kru Ram Muay (pre-fight ritual) create memorable visual impact. This drives 50-70% higher student purchase rates according to gym owner surveys. Team-branded shorts with traditional Thai patterns establish authentic martial arts identity. This separates serious Muay Thai programs from generic kickboxing classes.

Custom Muay Thai Shorts Manufacturing Process

Step 1: Design Consultation & Mockup

FitmanPro’s design team provides complete Muay Thai shorts customization. They offer several authentic styles. Traditional Thai satin style has classic shiny appearance with wide leg openings. Modern performance style uses moisture-wicking polyester with traditional cut. Hybrid style combines satin exterior with polyester interior lining. Competition style follows professional Muay Thai specifications for tournament use. Retro style features vintage Thai boxing aesthetics popular in 1980s-90s. Logo placement options include front thigh panels (traditional position), rear waistband area (gym branding), side leg panels (sponsor placement), and waistband embroidery (fighter name or gym name). You can customize with full sublimation printing on polyester (unlimited colors), traditional embroidery (authentic Thai look), screen printing (bold logos), and contrast piping (accent colors on seams). FitmanPro delivers initial design mockups within 24-48 hours. Unlimited revisions are included. They provide 3D rendering preview showing exact appearance.

Step 2: Fabric Selection & Construction

Satin Fabric (Traditional – 60% of Orders)

100% Satin (Classic Thai Boxing) provides authentic shiny appearance with smooth texture. This is best for traditional Muay Thai gyms and cultural authenticity. It offers lightweight feel with excellent drape. The fabric moves naturally during kicks and knees. Price ranges from $20-28 per short with 50-unit minimum order. Durability is 2-3 years with regular training (400-600 hours). This is popular with traditional Thai boxing schools and fighters wanting authentic look. The classic satin follows specifications from traditional Thai manufacturers. Hand-washing is recommended for longevity according to Muay Thai gear care guides.

Polyester-Spandex Blend (Modern Performance – 30% of Orders)

90% Polyester / 10% Spandex provides moisture-wicking performance with modern durability. This is best for intensive training and hot climate gyms. It offers quick-dry properties and machine-washable convenience. The fabric maintains color brilliance after 100+ washes. Price ranges from $22-32 per short with 50-unit minimum order. Durability is 3-4 years with regular training (800-1,000 hours). This is popular with modern kickboxing gyms and MMA crossover training. FitmanPro recommends this as best value for academy programs. Most contemporary Muay Thai gyms choose this option for practical benefits.

Microfiber Satin (Premium – 10% of Orders)

Microfiber Satin Blend combines satin appearance with microfiber durability. It provides classic shiny look with enhanced performance. This offers better moisture management than pure satin. The fabric resists wrinkles and maintains shape. Price ranges from $26-36 per short with 50-unit minimum order. Durability is 3-4 years with regular training. This is popular with professional fighters and premium gym brands. The microfiber construction follows modern combat sports textile standards.

All fabrics feature wide leg openings (12-16 inch circumference) for unrestricted kicking. High side slits (6-8 inches) allow extreme hip mobility. Lightweight construction (shorts weigh 3-5 oz) prevents restriction. Elastic waistband provides secure yet comfortable fit. Reinforced stitching at stress points ensures durability.

Step 3: Construction Features

Inseam Length Options

10-11 Inch Inseam (Short Traditional Fit) provides maximum leg freedom and unrestricted movement. This is best for traditional Muay Thai, high kicking, and flexibility-focused training. Thai fighters and competitive kickboxers prefer this option. It sits mid-thigh when standing. This follows traditional Thai boxing specifications.

12-13 Inch Inseam (Standard Fit – 70% of Orders) offers excellent balance of coverage and mobility. It works for Muay Thai training, kickboxing classes, and general striking work. Most Muay Thai practitioners choose this as their academy standard. It sits just above mid-thigh providing modest coverage. This is the most versatile length for different body types.

14 Inch Inseam (Long Fit) serves taller athletes and modest coverage preference. You get full mobility with slightly more coverage. Western practitioners and taller fighters (6’2″+) prefer this. It provides comfort for those transitioning from MMA shorts.

Waistband Construction Systems

Traditional Elastic Waistband (Standard – 90% of Orders) features wide elastic band (2-3 inches) with continuous stretch. The elastic provides comfortable fit during clinch work and cardio. No velcro or ties means no scratching or discomfort. It allows easy on/off between rounds. This is authentic Thai boxing construction. Price is included in base cost.

Elastic + Interior Drawstring (Modern Option) combines elastic waistband with internal drawstring adjustment. You get traditional comfort with extra security. The drawstring prevents slippage during intensive training. This is popular with Western kickboxing gyms. It costs an additional $2/short.

Premium Elastic (Competition Grade) uses reinforced elastic with anti-slip silicone lining. It provides maximum security during professional fights. The elastic maintains tension after 200+ washes. This is preferred by professional fighters. It costs an additional $3-4/short.

Side Slit Designs

Wide Side Slits (Traditional – 85% of Orders) feature 6-8 inch slits on each leg. This provides maximum hip mobility for roundhouse kicks and knee strikes. The wide openings allow full range teep (push kicks). According to Muay Thai mobility research, proper slits increase kick height by 15-20%. Traditional construction uses contrasting fabric trim on slits. This creates authentic Thai boxing aesthetic. Price is included in standard shorts.

Extreme Slits (Fighter Grade) offer 9-10 inch slits for professional flexibility. You get unrestricted movement for head kicks and flying knees. This is best for advanced fighters and competitors. It costs an additional $2/short.

Moderate Slits (Training Focused) feature 4-5 inch slits for balanced mobility and modesty. This provides good movement with more coverage. It’s popular for beginners and fitness kickboxing classes. Standard pricing applies.

Leg Opening Width

Wide Leg Opening (Traditional – 80% of Orders) measures 12-16 inches in circumference. This allows legs to move freely through full kicking range. The wide opening prevents fabric bunching during high kicks. This is authentic Muay Thai construction. According to fight gear comparison research, Muay Thai shorts have 30-40% wider leg openings than MMA shorts.

Standard Leg Opening (Modern) measures 10-12 inches for balanced fit. This provides mobility with slightly more tailored appearance. It’s popular with fitness kickboxing programs.

Step 4: Customization & Branding

Traditional Embroidery (Authentic Thai Style)

Traditional embroidery provides authentic Thai boxing appearance. You can add Thai script (gym name in Thai language). Symbols include sacred Yantra designs, Hanuman monkey god, twin tigers, and lotus flowers. Muay Thai glove emblems and Thai flag elements are popular. Embroidery placement includes front waistband (gym name), rear waistband (fighter name), and side leg panels (symbols or logos). Thread options include gold metallic thread (premium traditional look), silver metallic thread (modern aesthetic), and colored thread matching shorts. Cost ranges from $5-12 per short depending on complexity. This is best for traditional gyms and cultural authenticity.

Full Sublimation Printing (Modern Performance Shorts)

Sublimation allows unlimited design capability on polyester shorts. You can create photographic quality graphics with unlimited colors. There are no per-color charges. Complex patterns including Thai temple scenes, elephant motifs, traditional Thai patterns, geometric designs, and gradient effects are achievable. The dye infuses into the fabric. It’s permanent and never cracks or peels. Wash durability survives 200+ cycles without degradation. This follows ISO 105 colorfastness testing standards. Price is included in polyester short base cost. This is ideal for modern gyms and bold branding.

Screen Printing & Patches

Screen printing provides surface logos with bold, solid colors. You can choose matte or glossy finish. It works on both satin and polyester. Cost ranges from $3-5 per short for 1-2 colors. Durability is 50-100 washes. This works best for simple gym logos and sponsor patches.

Woven patches offer authentic Thai boxing look. You can create custom gym patches with traditional Thai border designs. Patches are sewn onto shorts (removable option available). Cost ranges from $4-7 per patch. This is popular for premium gym branding.

Contrast Piping & Trim

Contrast piping adds accent color to seams and edges. Traditional Thai shorts feature piping on waistband, leg slits, and bottom hem. You can choose from 15+ color options. It creates professional finished appearance. Cost is included in standard pricing for single color. Multiple colors cost an additional $2/short.

Custom Waistband Text

Waistband embroidery allows fighter name, gym name, or motivational text. Traditional placement is front center waistband. Text can be in English, Thai script, or custom language. Font options include traditional Thai style, modern block letters, and script fonts. Cost ranges from $6-10/short for name embroidery. This is best for competition teams and professional fighters.

Minimum Order Quantities & Pricing

FitmanPro MOQ Structure:

25-49 Units (Small Gym/Team) – Satin Traditional costs $26-32 per short. Polyester Performance costs $28-34 per short. Total investment is $650-1,666. Production time is 3-4 weeks. This is best for small Muay Thai gyms with 25-70 members and trial programs. Retail potential is $1,250-2,450 at $50/short retail. Profit is $600-784 with 92-120% markup.

50-99 Units (Most Popular – Mid-Size Gym) – Satin Traditional costs $20-28 per short. Polyester Performance costs $22-32 per short. Total investment is $1,000-3,168. Production time is 2-3 weeks. This is best for mid-size gyms with 70-150 members. Retail potential is $2,500-4,950 at $50/short retail. Profit is $1,500-1,782 with 150-178% markup. This is the volume sweet spot with best price-to-quality ratio.

100-249 Units (Large Gym/Multi-Location) – Satin Traditional costs $18-26 per short. Polyester Performance costs $20-29 per short. Total investment is $1,800-7,221. Production time is 2-3 weeks with priority scheduling. This is best for large gyms with 150+ members and 2-3 locations. Retail potential is $5,000-12,450 at $50/short retail. Profit is $3,200-5,229 with 177-289% markup. Perks include free sample shorts, priority production, and dedicated account manager.

250-499 Units (Distributor/Franchise) – Satin Traditional costs $16-24 per short. Polyester Performance costs $18-27 per short. Total investment is $4,000-13,473. Production time is 3-4 weeks. This is best for franchise networks, regional distributors, and emerging brands. Retail potential is $12,500-24,950 at $50/short retail. Profit is $8,500-11,477 with 212-286% markup. Perks include rush production available in 2 weeks, custom packaging, and volume shipping discounts.

500-999 Units (Private Label Brand) – Satin Traditional costs $14-22 per short. Polyester Performance costs $16-25 per short. Total investment is $7,000-24,975. Production time is 4-5 weeks. This is best for established brands, online retailers, and international distributors. Retail potential is $25,000-49,950 at $50/short retail. Profit is $18,000-24,975 with 257-357% markup. Perks include custom woven labels, hang tags, individual poly bags, and branded boxes.

1,000+ Units (Major Brand Partnership) – Satin Traditional costs $12-20 per short. Polyester Performance costs $14-23 per short. Total investment is $12,000-23,000. Production time is 5-6 weeks. This is best for major brands, national franchises, and professional fighter contracts. Retail potential is $50,000+ at $50/short retail. Profit is $38,000-27,000+ with 316-435% markup. Perks include dedicated production line, inventory management, and global logistics.

All prices include customization (embroidery or sublimation), standard features (elastic waistband, wide slits, traditional construction), and professional packaging. International shipping is quoted separately. Express production fees and premium add-ons (metallic embroidery, patches) cost additional.

Worldwide Shipping From Pakistan

FitmanPro ships custom Muay Thai shorts to 150+ countries. USA gets standard delivery in 16-20 days at $160-320 for 50-unit order. Express (DHL) takes 8-12 days at $280-500. Duty is usually $0-40 for sportswear. Canada gets standard in 18-22 days at $180-360. Express takes 10-14 days at $320-550. Mexico gets standard in 20-24 days at $200-400. UK, Germany, France get standard in 16-20 days at $200-400. Express takes 8-12 days at $360-600. Australia gets standard in 18-24 days at $220-450. Express takes 12-16 days at $400-700. Thailand gets standard in 12-16 days at $140-280 (popular for Thai gym orders). Express takes 7-10 days at $250-450. UAE, Singapore get standard in 10-16 days at $130-300. Express takes 6-10 days at $270-500. Muay Thai shorts are lightweight and compact. This means very low shipping costs per unit compared to gis.

Quality Control Process

FitmanPro 8-Point Quality Inspection includes fabric testing with fabric weight verification and drape testing (proper flow during movement). Colorfastness testing follows ISO 105 standards. Hand-wash simulation for satin shorts verifies durability. Embroidery quality verification checks thread tension and design accuracy versus approved mockup. Metallic thread sheen is inspected. There’s no puckering or thread breaks. Construction integrity check covers elastic waistband tension (consistent stretch recovery). Side slit measurements are verified (6-8 inches accurate). Leg opening width is checked (12-16 inches for traditional fit). Reinforced stress points are inspected. Stitching quality review includes flatlock seam inspection on leg openings. Waistband attachment strength is tested. Hem quality is verified. There are no loose threads or fraying. Sizing accuracy verification includes random measurement checks. Waist circumference, inseam length, and leg opening are measured. Sizes are consistent across all units. Functional testing includes stretch test (simulated kicking motion). Waistband security test ensures no rolling or slipping. Side slit flexibility is confirmed. Wash testing involves washing sample shorts 5+ cycles (satin hand-washed, polyester machine-washed). Embroidery durability is confirmed. There’s no color bleeding from contrast piping. Fabric maintains proper drape. Final visual inspection means each short is individually inspected. Embroidery alignment is checked. Stain and defect check is performed. Packaging is verified. Defect rate is less than 0.3% which is industry-leading. Replacement policy offers free replacement for manufacturing defects within 30 days.

Case Studies: Successful Custom Muay Thai Shorts Programs

Case Study 1: Traditional Muay Thai Gym (100 Members) ordered 80 custom satin Muay Thai shorts with gym logo and traditional Thai embroidery. Cost was $1,920 at $24/short for classic satin. Retail price was $60/short to members. Sales timeline was 3 months. They sold 68 shorts which is 85% sell-through. Revenue was $4,080. Profit was $2,160 with 112% markup. They kept 12 shorts for loaner and trial inventory. The gym owner said “Students love the authentic look. The traditional embroidery makes them feel connected to Muay Thai heritage. These sold better than our previous generic shorts.”

Case Study 2: Professional Muay Thai Fighter ordered 40 custom shorts with signature design and Thai script name. Cost was $1,080 at $27/short with premium metallic embroidery. The strategy was fighter wears shorts during ONE Championship fight and sells via social media. Retail price was $75/short which is premium pricing. Pre-orders before fight were 28 shorts generating $2,100 revenue. Post-fight sales over 4 months were 62 additional generating $4,650. Total was 90 shorts sold generating $6,750 revenue. Profit was $5,670 with 525% markup. Bonus was brand visibility to 2.5M ONE Championship broadcast viewers. The fighter said “My custom Muay Thai shorts became my signature. Fans wanted authentic Thai style with my branding. Made $5,600+ profit and built my personal brand.”

Case Study 3: Kickboxing Franchise (3 Locations, 280 Students) ordered 200 polyester performance shorts with modern sublimation design. Cost was $4,400 at $22/short volume discount. Sales channel was in-gym retail at all 3 locations. Retail price was $55/short. Over 5 months they sold 172 shorts which is 86% sell-through. Revenue was $9,460. Profit was $5,060 with 115% markup. Remaining inventory was 28 shorts valued at $1,540 retail. The franchise owner said “Modern polyester shorts work better for our fitness-focused members. Easy care and durability mean students actually wear them. Consistent branding across locations strengthens our brand identity.”

How to Order Custom Muay Thai Shorts From FitmanPro

Step-by-Step Process begins Day 1-2 with initial contact. You can use website fitmanpro.com, Instagram @fitman.pro (DM), email, or WhatsApp. Provide your gym/brand/fighter name, desired quantity, fabric preference (satin or polyester), design ideas or reference images, logo files (PDF, AI, PNG), Thai script text if desired, and timeline requirements.

Day 3-5 is design and mockup phase. You receive 3D mockup showing front, back, and side views. You get multiple colorway options. Traditional Thai design suggestions are provided if requested. Size chart recommendations are included. You receive detailed quote. You can make unlimited design changes. Adjust embroidery, colors, piping, and placement.

Day 6-7 is quote and payment. Quote includes unit price based on quantity, customization costs (embroidery or sublimation), packaging, shipping estimate, and total investment. Payment requires 50% deposit to start production. You pay 50% balance before shipping. Payment methods are PayPal, Wire Transfer, or Western Union.

Day 8-28 is production which takes 2-3 weeks. Week 1 covers fabric cutting and embroidery digitization (if applicable). Week 2 is embroidery application or sublimation printing and initial assembly. Week 3 is final assembly, piping attachment, quality control, and packaging. You get progress photos every 5-7 days. Pre-shipment approval photos are sent showing embroidery detail.

Day 29-50 is shipping and delivery. Tracking number is provided. Standard delivery takes 14-20 days. Express takes 7-12 days. Customs support is included. Total timeline is 29-50 days for Standard or 22-35 days for Express.

Design Best Practices

Traditional Thai Design Elements include sacred Yantra symbols which are spiritual protection tattoo designs popular in Thai culture. Hanuman (monkey god) represents strength and loyalty in Thai mythology. Twin tigers symbolize power and ferocity. Lotus flowers represent purity and enlightenment. Thai temple silhouettes create cultural connection. Elephant motifs honor Thailand’s national symbol. Traditional Thai patterns include geometric borders and ornamental designs. Color meanings include red for courage and power, blue for royalty and honor, gold/yellow for prosperity and respect, black for strength and authority, and white for purity and peace.

Logo Placement Strategy uses front thigh panels as primary placement. Optimal size is 4″x4″ to 6″x6″ per leg. This offers visibility during stance and kicks. Typical use is main gym logo on left thigh and Thai symbol on right thigh.

Front waistband center has optimal size 4″x6″ to 6″x8″. This provides visibility during weigh-ins and photos. Typical use is gym name in English or Thai script.

Rear waistband has optimal size 6″x3″ to 8″x4″. This provides visibility during training and rear angles. Typical use is fighter name or sponsor logo.

Side leg panels have optimal size 3″x3″ to 4″x4″. This offers visibility during kicks and movement. Typical use is small emblems or secondary sponsors.

Color Combinations for traditional looks include red body with gold trim and embroidery, blue body with white or silver trim, black body with gold or red accents, white body with any contrast color trim, and gold/yellow body with red or blue trim. For modern looks try gradient designs, multi-color Thai patterns, camouflage with Thai elements, neon colors with traditional symbols, and custom brand color matching.

Maintenance & Care

Washing instructions differ by fabric type. Satin Shorts Care requires hand-washing in cold water for best longevity. Use mild detergent only. Never use bleach or harsh chemicals. Gently squeeze water out without wringing. Hang to air dry away from direct sunlight. Never machine dry satin shorts. Iron on low heat if needed using pressing cloth. This preserves satin sheen according to Muay Thai shorts care guides. Expected lifespan is 2-3 years with proper care (400-600 training hours).

Polyester Shorts Care allows machine washing on gentle cycle. Use cold water only. Turn inside-out to protect sublimation printing. Use mild detergent. Avoid fabric softener. Air dry for best results. You can use low heat machine drying if needed. Never use high heat because it damages elastane and printing. American Cleaning Institute research confirms cold water washing preserves fabric colors and elasticity. Expected lifespan is 3-4 years (800-1,000 training hours).

Storage requires hanging or folding in dry area. Never store damp. Keep satin shorts in breathable garment bag. Avoid crushing satin fabric under heavy items. Store away from direct sunlight to prevent fading.

Frequently Asked Questions

Q: What’s the minimum order for custom Muay Thai shorts?
A: 25 units minimum. This is industry-low for premium custom manufacturing.

Q: Can I mix sizes in one order?
A: Yes. Provide breakdown like 10 Small, 20 Medium, 15 Large, 5 XL.

Q: What’s the difference between satin and polyester?
A: Satin offers authentic traditional look with shiny appearance. It requires hand-washing. Polyester offers modern performance with easier care. It’s machine-washable and more durable.

Q: Can you do Thai script embroidery?
A: Yes. Provide Thai text or English text for translation. Our team verifies accurate Thai script before production.

Q: How do Muay Thai shorts differ from MMA shorts?
A: Muay Thai shorts are shorter (10-14 inch inseam vs 9-11 inch for MMA). They have wider leg openings for kicking. They use elastic waistband only (no velcro). According to fight shorts comparison research, Muay Thai shorts prioritize striking mobility while MMA shorts balance striking and grappling.

Q: Can fighters wear these in professional Muay Thai competitions?
A: Yes. Our shorts meet traditional Muay Thai competition standards. Check specific event rules for sponsor logo size restrictions.

Q: Do you offer women’s specific sizes?
A: Yes. We offer women’s cuts with adjusted waist-to-hip ratio and sizing options.

Q: Can I get samples before bulk order?
A: Yes. Samples cost $40-60 each including shipping. Cost is credited toward 50+ unit orders.

Q: What if I need rush production?
A: Express production is available. It takes 7-10 days production plus 7-10 day express shipping. There’s a 25% upcharge.

Q: Can you match traditional Thai brand quality?
A: Yes. FitmanPro uses same construction techniques and materials as premium Thai manufacturers. Many Thai gym owners order from us for consistent quality at better pricing.

Related Resources

Internal BJJ Sportswear Guides:

• Custom MMA Shorts – MMA fight shorts with grappling features
• Custom BJJ Rash Guards – No-gi top solution
• Custom BJJ Gi Guide – Traditional gi manufacturing
• Gi vs No-Gi Training – Understanding combat sports gear
• Is BJJ Good for MMA? – MMA training integration
• BJJ Hygiene Tips – Equipment care importance
• What is BJJ? – Complete introduction

External Combat Sports Resources:

• ONE Championship – Asian MMA and Muay Thai organization
• Hayabusa Muay Thai Guide – Fight gear specifications
• Muay Thai Shorts Size Guide – Industry sizing standards
• Traditional Muay Thai Factory – Authentic Thai specifications
• Muay Thai Shorts Care Guide – Maintenance and washing
• Muay Thai vs MMA Shorts – Design differences explained
• ASTM Textile Standards – Industry fabric testing
• ISO Quality Standards – Manufacturing certification
• American Cleaning Institute – Textile care research

Custom Muay Thai Shorts – Equip your gym, sponsor professional fighters, or launch your fight gear brand. Get authentic Thai boxing shorts with traditional satin or modern polyester construction. Manufactured by Pakistan’s leading combat sports factory. Ships to 150+ countries. Features wide leg openings and high side slits for maximum kicking mobility. Includes traditional embroidery or sublimation printing. Complete customization available. Minimum 25-unit orders to 1,000+ private label production runs.

Get your free design mockup today: Contact FitmanPro