Custom BJJ Spats: Manufacturing & Design Guide (2026)

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Custom BJJ Spats: Manufacturing & Design Guide (2026)

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

Custom BJJ spats are compression leggings designed for no-gi grappling and mixed martial arts training. Gyms, competition teams, and brands order 50-500+ units at $16-32 per spat. The price depends on fabric weight (200-240 GSM), length (full-length or 3/4), and customization features. These features include full sublimation printing, reinforced stitching, elastic waistband, and antimicrobial treatment. Pakistan-based manufacturers like FitmanPro in Sialkot offer premium compression spats. They use 88% polyester / 12% spandex blend fabric. FitmanPro ships to 150+ countries worldwide. Their customers include BJJ practitioners, MMA fighters, wrestlers, and grappling academies. Academies can make 50-70% retail markup on custom spats.

Why Custom BJJ Spats Drive Revenue & Training Comfort

No-Gi Essential & Multi-Purpose Appeal

BJJ spats serve the growing no-gi grappling market. According to Zenjo martial arts research, spats keep muscles warm during training. This prevents muscle pulls and sprains. Spats protect skin from mat burn during ground fighting. They provide compression that improves blood circulation. Many grapplers wear spats under gi pants for comfort.

According to grappling benefits research, compression spats increase friction for better leg grips in no-gi. Custom-branded spats generate $5,000-18,000 annually for mid-size gyms with 100-200 members. Gyms buy them wholesale at $16-32 per spat. Then they sell them retail at $45-75 per spat. This creates 180-340% markup. Spats paired with custom rash guards create complete no-gi uniform.

Year-Round Revenue Stream

Unlike seasonal gear, spats sell consistently throughout the year. They work for all martial arts training including no-gi BJJ, MMA, wrestling, and grappling. Spats also appeal to fitness markets. CrossFit athletes use them for workouts. Yoga practitioners wear them for flexibility training. Runners use them for cold weather. This multi-purpose appeal drives 60-80% higher sell-through rates compared to gi-specific gear. Custom spats with bold designs create walking advertisements when students wear them outside the gym.

Custom BJJ Spats Manufacturing Process

Step 1: Design Consultation & Mockup

FitmanPro’s design team provides complete spats customization. They offer several style options. Full-length spats (ankle-length) are the most popular choice for complete coverage. 3/4 length spats (mid-calf) work for hot climates and smaller athletes. Capri length spats (below knee) are popular with women. Competition style follows IBJJF no-gi regulations for tournament use. Training style offers relaxed fit for daily practice. Logo placement options include side leg panels (most visible during rolling), front thigh panels (visible when standing), rear waistband area (sponsor showcase), and full-body designs (all-over sublimation patterns).

You can customize with full sublimation printing (unlimited colors, photographic quality), bold graphic designs (team logos, mascots, abstract patterns), sponsor placement zones (multiple logos integrated), contrast panels (accent color blocks), and custom waistband text (gym name or athlete name). FitmanPro delivers initial design mockups within 24-48 hours. Unlimited revisions are included. They provide 3D rendering preview showing exact appearance on body.

Step 2: Fabric Selection & Construction

Compression Fabric (Standard – 95% of Orders)

200 GSM Lightweight Compression provides maximum breathability and quick-dry performance. This is best for hot climate training and intensive rolling sessions. It offers excellent moisture-wicking with 4-way stretch mobility. The fabric maintains compression after 100+ washes. Price ranges from $16-24 per spat with 50-unit minimum order. Durability is 2-3 years with regular training (500-700 hours). This is popular with competition grapplers and warm-weather academies. The lightweight construction follows modern compression wear standards.

220 GSM Standard Compression (Most Popular) provides balanced compression with professional durability. This is best for daily training and all-season use. It offers moderate compression that supports muscles without restriction. The fabric has superior shape retention. Price ranges from $18-28 per spat with 50-unit minimum order. Durability is 3-4 years with regular training (800-1,000 hours). This is popular with most BJJ academies and MMA gyms.

FitmanPro recommends this as best value for academy programs. The 88% polyester / 12% spandex blend is industry standard. This composition provides optimal stretch and recovery according to Reddit BJJ community feedback.

240 GSM Heavy-Duty Compression provides maximum compression and cold-weather comfort. This is best for intensive grappling and winter training. It offers thick fabric that prevents transparency when stretched. The fabric provides muscle support during explosive movements. Price ranges from $20-32 per spat with 50-unit minimum order. Durability is 4-5 years with regular training (1,200+ hours). This is popular with professional fighters and hard-training academies. The heavy-duty construction prevents see-through issues common with cheap spats.

All compression fabrics feature 4-way stretch for unrestricted movement during guard work. Moisture-wicking technology dries 6x faster than cotton. Antimicrobial treatment prevents odor and bacteria growth. Flatlock stitching prevents chafing during ground fighting. Reinforced gusset provides freedom of movement. Non-slip elastic waistband prevents rolling during training. Colorfast dye means no fading after 150+ washes following ISO 105 colorfastness standards.

Step 3: Construction Features

Length Options

Full-Length (Ankle-Length – 70% of Orders) provides complete leg coverage from waist to ankle. This is best for all-around training and maximum skin protection. It prevents mat burn on shins and ankles. Most grapplers prefer this as their standard length. It works for all seasons and training styles. This follows traditional BJJ spats design.

3/4 Length (Mid-Calf – 20% of Orders) offers coverage to mid-calf with easier on/off. This is best for hot climate training and smaller athletes. It provides good coverage with less fabric. It’s popular with fighters who dislike full ankle coverage. This works well for summer training camps.

Capri Length (Below Knee – 10% of Orders) provides coverage to just below knee. This is best for women’s training and CrossFit crossover. It offers modest coverage with maximum ventilation. It’s popular with female practitioners. This style bridges training and casual wear.

Waistband Construction

Standard Elastic Waistband (90% of Orders) features wide elastic band (2-3 inches) with continuous stretch. The elastic provides comfortable fit during guard work and inversions. It stays in place without rolling or slipping. Silicone grip strips inside prevent movement. This is included in base price. The waistband withstands repeated washing without losing elasticity.

High-Rise Waistband (Modern Option) offers extra-wide elastic band (3-4 inches) sitting above hips. This provides maximum security during explosive movements. It prevents exposure during inverted positions. This is popular with female grapplers and CrossFit athletes. It costs an additional $2/spat.

Drawstring Waistband (Premium) combines elastic with internal drawstring adjustment. This provides customizable fit for different body types. The drawstring prevents any slippage during training. This is preferred by professional fighters. It costs an additional $3/spat.

Reinforcement Features

Reinforced Gusset (Standard) includes diamond-shaped panel at crotch area. This prevents tearing during deep squats and guard work. The gusset allows full range of motion. It’s constructed with double-layer fabric. This is included in all spats. The reinforcement extends spats lifespan by 40-60%.

Knee Reinforcement (Optional) features double-layer fabric panels at knees. This provides extra durability during kneeling and wrestling shots. It prevents wear-through at high-stress areas. This costs an additional $3-4/spat. It’s popular with wrestlers and takedown-focused grapplers.

Flatlock Stitching (Standard) uses specialized seam construction that lies flat against skin. This prevents chafing during ground fighting. According to Fusion Fight Gear specifications, flatlock stitching withstands toughest wear and tear. All seams are reinforced for durability. This is included in base price.

Step 4: Customization & Branding

Full Sublimation Printing

Sublimation allows unlimited design capability on polyester spats. You can create photographic quality graphics with unlimited colors. There are no per-color charges. Complex patterns including team mascots, abstract geometric designs, gradient fades, camouflage patterns, tribal designs, and full-body graphics are achievable. The dye infuses into the fabric. It’s permanent and never cracks or peels. The design won’t fade during guard work or mat friction.

Wash durability survives 200+ cycles without degradation. This follows ISO 105 colorfastness testing standards. Price is included in base cost. This allows unlimited creativity for bold branding.

Logo Placement Strategy

Side Leg Panels (Most Popular) feature logos running down outer thigh and calf. Optimal size is 4″x20″ to 6″x24″ vertical design. This offers maximum visibility during rolling and standing. Typical use is main gym logo on left leg and sponsor logo on right leg. This placement is visible in all training positions.

Front Thigh Panels display logos on front of each thigh. Optimal size is 6″x6″ to 8″x8″ per leg. This provides visibility during standup and guard play. Typical use is bilateral gym branding or mascot design. This works well for symmetric designs.

Rear Waistband Area shows logos across lower back and glutes. Optimal size is 8″x4″ to 12″x6″. This provides visibility during back control and turtle position. Typical use is secondary sponsors or motivational text. This area gets good camera exposure during competitions.

All-Over Design creates full-body sublimation patterns. The design covers entire spats from waist to ankle. This provides maximum brand impact and unique appearance. Typical use is team colors with integrated logos throughout. This creates strongest visual identity.

Design Themes & Styles

Bold Geometric Patterns use triangles, hexagons, and angular shapes. These create modern athletic appearance. They’re popular with younger practitioners and MMA gyms. Colors typically include black, red, blue, neon accents.

Traditional Martial Arts Motifs feature samurai themes, Japanese waves, dragon designs, and Asian calligraphy. These connect to martial arts heritage. They’re popular with traditional BJJ academies. Colors typically include black, gold, red, white.

Camouflage & Tactical Designs use digital camo, woodland patterns, and military aesthetics. These appeal to law enforcement and military practitioners. They’re popular with self-defense focused academies. Colors typically include black, grey, green, tan.

Team Color Blocking uses solid color panels with accent stripes. These create clean professional appearance. They’re popular with competition teams wanting unified look. Colors match team identity and school colors.

Licensed Character Designs feature pop culture characters and gaming references. These create fun training environment. They’re popular with youth programs and casual grapplers. Designs require licensing agreements for official use.

Custom Waistband Text

Waistband printing allows gym name, athlete name, or motivational text. Traditional placement is rear center waistband. Text can be in any language or font style. Large text (2-3 inches tall) is visible during training. Small text (1 inch) provides subtle branding. Cost is included in sublimation pricing. This personalizes spats for individual athletes or teams.

Minimum Order Quantities & Pricing

FitmanPro MOQ Structure:

25-49 Units (Small Gym/Team) – 220 GSM Standard costs $24-32 per spat. Total investment is $600-1,568. Production time is 3-4 weeks. This is best for small BJJ academies with 30-80 members and trial programs. Retail potential is $1,125-2,450 at $45/spat retail. Profit is $525-882 with 87-176% markup.

50-99 Units (Most Popular – Mid-Size Gym) – 220 GSM Standard costs $18-28 per spat. Total investment is $900-2,772. Production time is 2-3 weeks. This is best for mid-size gyms with 80-200 members. Retail potential is $2,250-4,950 at $50/spat retail. Profit is $1,350-2,178 with 150-242% markup. This is the volume sweet spot with best price-to-quality ratio.

100-249 Units (Large Gym/Multi-Location) – 220 GSM Standard costs $16-26 per spat. Total investment is $1,600-6,474. Production time is 2-3 weeks with priority scheduling. This is best for large gyms with 200+ members and 2-3 locations. Retail potential is $5,000-12,450 at $50/spat retail. Profit is $3,400-5,976 with 212-371% markup. Perks include free sample spats, priority production, and dedicated account manager.

250-499 Units (Distributor/Franchise) – 220 GSM Standard costs $14-24 per spat. Total investment is $3,500-11,976. 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/spat retail. Profit is $9,000-12,974 with 257-370% markup. Perks include rush production available in 2 weeks, custom packaging, and volume shipping discounts.

500-999 Units (Private Label Brand) – 220 GSM Standard costs $12-22 per spat. Total investment is $6,000-21,978. 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/spat retail. Profit is $19,000-27,972 with 316-467% markup. Perks include custom woven labels, hang tags, individual poly bags, and branded boxes.

1,000+ Units (Major Brand Partnership) – 220 GSM Standard costs $10-20 per spat. Total investment is $10,000-19,980. 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/spat retail. Profit is $40,000-30,020+ with 400-600% markup. Perks include dedicated production line, inventory management, and global logistics.

All prices include full sublimation printing, standard features (elastic waistband, reinforced gusset, flatlock stitching, antimicrobial treatment), and professional packaging. International shipping is quoted separately. Express production fees and premium add-ons (knee reinforcement, drawstring waistband) cost additional.

Worldwide Shipping From Pakistan

FitmanPro ships custom BJJ spats to 150+ countries. USA gets standard delivery in 16-20 days at $140-300 for 50-unit order. Express (DHL) takes 8-12 days at $250-450. Duty is usually $0-35 for sportswear. Canada gets standard in 18-22 days at $160-340. Express takes 10-14 days at $280-500. Mexico gets standard in 20-24 days at $180-380. UK, Germany, France get standard in 16-20 days at $180-380. Express takes 8-12 days at $320-550.

Australia gets standard in 18-24 days at $200-420. Express takes 12-16 days at $360-650. Brazil gets standard in 22-28 days at $240-500. Express takes 15-20 days at $400-750. UAE, Singapore get standard in 10-16 days at $120-280. Express takes 6-10 days at $240-450. Spats are very lightweight and compact. This means lowest shipping costs per unit compared to all other fight gear.

Quality Control Process

FitmanPro 10-Point Quality Inspection includes fabric testing with GSM weight verification and stretch recovery testing (4-way stretch confirmed). Compression level testing ensures proper muscle support. Colorfastness testing follows ISO 105 standards. Pre-production wash test measures shrinkage (should be under 3%). Print quality verification checks sublimation accuracy versus approved design. Color vibrancy is inspected under different lighting. Design alignment is verified on body curves. There’s no color bleeding or fading. Construction integrity check covers reinforced gusset inspection (double-layer verified).

Waistband elastic tension is tested (no rolling during movement). Flatlock seam quality is inspected (lies completely flat). Reinforced stress points are verified at waist and ankles. Stitching quality review includes all seams checked for strength. Thread tension is standardized across production. There are no loose threads or puckering. Seams withstand 50-pound pull test. Sizing accuracy verification includes random measurement verification. Waist circumference, inseam length, and leg circumference are checked. Rise measurement is verified (front to back through crotch). Sizes are consistent across all units within 1cm tolerance. Functional testing includes stretch test simulating guard work and inversions. Waistband security test ensures no slipping during movement.

Transparency check confirms no see-through when stretched. Compression test verifies proper muscle support level. Antimicrobial treatment verification confirms chemical application. Odor resistance is tested after simulated training session. Treatment remains effective after 50+ washes. Wash testing involves washing sample spats 10+ cycles. Sublimation durability is confirmed (no fading or cracking). Elastic maintains 90%+ of original tension. Fabric maintains shape without sagging. Final visual inspection means each spat is individually inspected. Print quality is verified across all panels. Stain and defect check is performed. Packaging is verified. Defect rate is less than 0.2% which is industry-leading. Replacement policy offers free replacement for manufacturing defects within 30 days.

Case Studies: Successful Custom Spats Programs

Case Study 1: No-Gi Focused BJJ Gym (120 Members) ordered 100 custom spats with bold geometric design matching their rash guards. Cost was $2,200 at $22/spat for 220 GSM compression. Retail price was $55/spat to members. Sales timeline was 4 months. They sold 84 spats which is 84% sell-through. Revenue was $4,620. Profit was $2,420 with 110% markup. They kept 16 spats for retail inventory. The gym owner said “Spats sold even better than rash guards. Students love wearing matching sets. The bold design creates great gym identity when students wear them outside training.”

Case Study 2: Competition Team (35 Athletes) ordered 50 custom spats with team logo and individual athlete names on waistband. Cost was $1,250 at $25/spat including name customization. The strategy was required uniform for competition team members. Retail price was $65/spat. They sold all 50 spats to team members at required purchase. Revenue was $3,250. Net cost for team uniforms was $0 (fully funded by sales). Bonus was unified appearance at IBJJF tournaments creating professional brand image. Team coach said “Custom spats elevated our team’s professional appearance. Opponents took us more seriously. The unified look boosted team morale and pride.”

Case Study 3: Women’s BJJ Program (80 Members) ordered 60 high-rise capri length spats with feminine design. Cost was $1,380 at $23/spat for capri style. Sales channel was in-gym retail targeting female members. Retail price was $60/spat. Over 3 months they sold 52 spats which is 87% sell-through. Revenue was $3,120. Profit was $1,740 with 126% markup. Remaining inventory was 8 spats valued at $480 retail. Program coordinator said “Women-specific design was key. High-rise waistband and shorter length addressed our female students’ preferences. These sold much better than generic full-length spats we previously stocked.”

Case Study 4: Online BJJ Brand ordered 300 spats with licensed martial arts character designs. Cost was $4,200 at $14/spat volume discount. Sales channel was website and social media marketing. Retail price was $49.99/spat (competitive online pricing). Over 6 months they sold 267 spats which is 89% sell-through. Revenue was $13,347. Profit was $9,147 with 218% markup. Remaining inventory was 33 spats valued at $1,650 retail. Brand owner said “Spats have highest profit margins of all our products. Low shipping costs mean better margins than gis. The bold designs photograph well for social media marketing driving organic sales.”

How to Order Custom BJJ Spats 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/team name, desired quantity, preferred length (full, 3/4, or capri), design ideas or reference images, logo files (PDF, AI, PNG), color scheme preferences, and timeline requirements.

Day 3-5 is design and mockup phase. You receive 3D mockup showing front, back, and side views on body form. You get multiple colorway options. Design variations are provided for comparison. Size chart recommendations are included based on your demographic. You receive detailed quote. You can make unlimited design changes. Adjust logos, colors, patterns, and placement until perfect.

Day 6-7 is quote and payment. Quote includes unit price based on quantity, customization costs (included in sublimation), size breakdown options, packaging choices, shipping estimate to your country, and total investment required. Payment requires 50% deposit to start production. You pay 50% balance before shipping. Payment methods are PayPal (buyer protection), Wire Transfer (lower fees for large orders), or Western Union.

Day 8-28 is production which takes 2-3 weeks. Week 1 covers fabric cutting with computer-aided precision and sublimation printing (heat-press dye infusion). Week 2 is panel assembly, flatlock seam construction, gusset attachment, and waistband assembly. Week 3 is quality control inspection (10-point check), antimicrobial treatment application, individual packaging, and pre-shipment photos. You get progress photos every 5-7 days. Pre-shipment approval photos show final product quality before shipping initiated.

Day 29-50 is shipping and delivery. Tracking number is provided via email and SMS. Standard delivery takes 14-20 days depending on country. Express takes 7-12 days for urgent orders. Customs support documentation is included (commercial invoice, packing list, origin certificate). Total timeline is 29-50 days for Standard or 22-35 days for Express.

Design Best Practices

Color Psychology & Team Branding shows black spats (35% of orders) provide versatile base for any logo colors. They hide dirt and wear well. They’re popular with traditional academies and professional teams. Blue spats (25%) create trust and team unity. They work well with most gym colors. They’re popular with established academies. Red spats (20%) convey aggression and intensity. They stand out during competitions. They’re popular with competition-focused teams. Multi-color designs (20%) create unique brand identity. They maximize visual impact. They’re popular with youth programs and modern gyms.

Logo Sizing Guidelines recommend side leg panel logos at 4-6 inches wide by 16-24 inches tall. This creates strong vertical branding visible during all positions. Front thigh logos should be 6-8 inches square for bilateral symmetry. This works well for mascots and circular logos. Rear waistband logos should be 8-12 inches wide by 4-6 inches tall. This maximizes sponsor visibility in back-facing positions. All-over patterns should integrate logos at 3-4 different scales. This creates cohesive design without overwhelming appearance.

Design Complexity Balance suggests limiting colors to 3-5 main colors for clean appearance. Too many colors create visual chaos. Use gradients and fades to add depth without extra colors. Keep primary logo placement clear and bold. Secondary elements should complement not compete with main branding. Test designs on body mockup from 10 feet away. If logo is readable from distance it’s well-sized.

Maintenance & Care

Washing instructions require washing after every use within 6 hours. This prevents bacteria growth and odor. Use cold water only to preserve elasticity. Turn inside-out to protect sublimation printing. Use gentle cycle or hand-wash for best results. Use mild detergent without fabric softener. Fabric softener breaks down spandex fibers over time. According to American Cleaning Institute research, cold water preserves compression fabrics 4x longer than hot water.

Drying requires air drying for maximum lifespan. Hang or lay flat in well-ventilated area. Avoid direct sunlight which fades colors over time. You can use low heat machine drying if needed. Never use high heat because it damages spandex permanently. High heat causes permanent loss of compression and elasticity. Remove promptly to prevent wrinkles.

Storage requires hanging or rolling rather than folding. Folding creates permanent creases in compression fabric. Store in cool, dry area away from heat sources. Never store damp because mildew grows in 24-48 hours. Keep away from sharp objects that could snag fabric.

Special care tips include pre-soaking heavily soiled spats in cold water for 30 minutes. This loosens dirt before washing. Avoid washing with rough fabrics like gis with patches. Rough surfaces can pill compression fabric. Separate dark colors from light colors for first 3-5 washes. This prevents any minor color bleeding during break-in period.

Expected lifespan is 800-1,200 training hours which equals 3-4 years regular use (3-4x per week training). Proper care extends lifespan up to 50% beyond cheap spats with poor care.

Frequently Asked Questions

Q: What’s the minimum order for custom BJJ spats?
A: 25 units minimum. This is industry-low for premium custom compression spats.

Q: Can I mix sizes in one order?
A: Yes. Provide breakdown like 10 Small, 20 Medium, 15 Large, 5 XL. We offer full size range from XXS to 3XL.

Q: Are BJJ spats just compression pants?
A: No. According to Reddit BJJ community, BJJ spats use thicker fabric to prevent transparency. They have reinforced gussets for grappling. Regular compression pants are often see-through when stretched.

Q: Can women wear men’s spats?
A: Yes, but women-specific cuts provide better fit. We offer high-rise waistband and adjusted hip-to-waist ratio for female body types.

Q: How long does sublimation printing last?
A: Permanent. Dye is bonded to fabric at molecular level. It survives 200+ washes without fading.

Q: Can fighters wear these in IBJJF no-gi competitions?
A: Yes, if designed to specifications. Current IBJJF no-gi rules allow spats in black or matching rash guard colors. Logo size restrictions apply. FitmanPro advises on compliance during design.

Q: Do you offer different compression levels?
A: Yes. We offer light (200 GSM), medium (220 GSM), and firm (240 GSM) compression. Most grapplers prefer medium 220 GSM.

Q: Can I get samples before bulk order?
A: Yes. Samples cost $35-55 each including shipping. Cost is credited toward 50+ unit orders placed within 90 days.

Q: What if sizing is wrong?
A: We provide detailed size charts with measurements. Size accuracy guaranteed within 1cm. If manufacturer error, free remake. If client error (wrong size chart selection), remake available at production cost.

Q: How do I prevent my spats from becoming see-through?
A: Order 220 GSM or 240 GSM weight. Avoid 200 GSM for lighter-skinned individuals. Dark colors (black, navy, dark purple) prevent transparency better than light colors.

Internal BJJ Sportswear Guides:

External Combat Sports Resources:

Custom BJJ Spats – Complete your no-gi training gear with premium compression spats. Manufactured by Pakistan’s leading combat sports factory. Ships to 150+ countries. Features 88% polyester / 12% spandex compression fabric. Includes full sublimation printing and antimicrobial treatment. Perfect for BJJ, MMA, wrestling, and grappling. Complete customization available. Minimum 25-unit orders to 1,000+ private label production runs.

Get your free design mockup today: Contact FitmanPro

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