BJJ Gi Manufacturer for United States Brands

BJJ is one of the fastest-growing combat-sports markets in the US (estimated 800K+ active practitioners in 2026), and we've manufactured for about 18 US BJJ brands since 2019. Most are gym-affiliated (each gym wants their own private-label academy gi) or DTC brands targeting the hobbyist tier. Pearl weave fabric weights: 350 GSM (light competition), 450 GSM (standard competition), 550 GSM (heavyweight training). All three are pre-shrunk on receipt and tested for IBJJF compliance (collar thickness, lapel width, sleeve length, gi-pants gusset). For brands selling into the competition market, the 350 GSM is the most popular because IBJJF rules are stricter on heavy gis. Real landed cost for a 450 GSM standard pearl weave gi at 100-pc MOQ to a US 3PL: ~$28 FOB Karachi + $2.50 sea freight + $5 US import duty (15.6% on cotton garments) + $0.60 3PL = $36 landed. Sells at retail $90-150 for the premium hobbyist tier. Decoration: embroidery on chest, sleeve, and lapel; printed patches; custom labels; contrast collar/cuff color; private label hangtags. IBJJF-legal patch positions are documented in their rulebook — we follow it. Custom academy/team patches go through us as a digitizing service ($30-50 per logo, 48-hour turnaround). Pants are sold separately or as part of a gi+pants set. The pants weight typically matches the gi (450 GSM gi → 350-400 GSM ripstop cotton pants). Drawstring or cord-loop closure standard. What we don't compete on: kids gis under $15 FOB. The construction cost on kids gis (smaller fabric quantities, smaller patterns, but same labor) doesn't favor Pakistan at sub-$15 retail. Vietnamese factories do this better.