Custom Rash Guards: Sublimation Guide for BJJ & MMA Brands

Custom rash guards are one of the most popular private label products in the martial arts industry — and for good reason. They are relatively low-cost to produce, have strong margins, and every BJJ, MMA, and grappling athlete needs them. With sublimation printing, you can create any design imaginable with no extra cost per color. This guide covers everything you need to know before ordering your first batch.

1. What Is Sublimation Printing?

Sublimation is a printing process where ink is transferred directly into the fabric using heat and pressure. Unlike screen printing or heat transfer printing, sublimation does not sit on top of the fabric — it becomes part of the fiber. This means:

• The print never cracks, peels, or fades with washing
• You can print unlimited colors at no extra cost
• Full-surface, edge-to-edge designs are possible
• The fabric remains soft and breathable — no rubber or plastic feel
• Photorealistic images and gradients are achievable

Sublimation only works on polyester-based fabrics (or fabrics with high polyester content). For rash guards, which are naturally polyester or spandex blended, sublimation is the ideal printing method. Cotton garments cannot be sublimation printed.

2. Rash Guard Fabric Types

The most common fabrics used for BJJ and MMA rash guards are:

Fabric	Composition	Best For
Polyester-Spandex	82% Polyester / 18% Spandex	Standard BJJ rash guards — most common
Nylon-Spandex	80% Nylon / 20% Spandex	Premium rash guards — softer feel
4-Way Stretch	Poly-Spandex blend	Competition rash guards — max mobility
Compression Fabric	High spandex content	Performance compression rash guards

For most BJJ academies, the 82/18 polyester-spandex blend is the industry standard. It holds sublimation prints well, stretches adequately for grappling, dries quickly, and is cost-effective for wholesale orders. Nylon-spandex is the upgrade option for premium product lines.

3. Long Sleeve vs Short Sleeve vs Spats

Rash guards come in several styles, and many academies order all three. Here is when each makes sense:

• Long Sleeve Rash Guards: The most popular for BJJ. Provides full arm coverage and skin protection during mat grappling. Preferred for gi and no-gi training.
• Short Sleeve Rash Guards: Preferred for Muay Thai and MMA striking-based training. More breathable. Also popular in hot climates.
• Spats (Compression Leggings): Worn under shorts or gi pants. Commonly ordered together with rash guards as a matching set. Very popular for no-gi BJJ.
• Women's Cut: A separate pattern specifically designed for women. Do not use a unisex cut for women's orders — the fit difference significantly affects satisfaction.

4. How to Prepare Your Design File

This is the step where most first-time buyers get confused. Here is what your factory needs from you:

• File Format: AI (Adobe Illustrator) or PDF vector format is preferred. High-resolution PNG or JPEG (minimum 300 DPI) is acceptable if vector is not available.
• Color Mode: CMYK, not RGB. Colors look different on screen (RGB) vs printed on fabric (CMYK). Ask your designer to work in CMYK from the start.
• Template: A good factory will provide a flat technical template showing front, back, and sleeves. Design on this template so you can see exactly how the design wraps.
• Bleed Area: Extend your design 1–2cm beyond the seam lines. This ensures no white gaps appear at the edges when the garment is cut and sewn.
• Text: Convert all text to outlines before sending. This prevents font substitution issues at the factory.

At Nexpro Exports we provide design templates for all rash guard styles free of charge when you request a quote. If you have a logo but no full design, our in-house design team can create a complete layout for you.

5. Sizing and Size Runs

Sizing for compression garments runs differently from regular clothing. Here is the standard sizing guide for adult rash guards:

Size	Height	Chest (inches)	Weight (kg)
XS	155–163 cm	32–34"	50–60
S	163–170 cm	34–36"	60–70
M	170–178 cm	36–40"	70–82
L	178–185 cm	40–44"	82–95
XL	183–190 cm	44–48"	95–110
2XL	188–196 cm	48–52"	110+

When ordering a size run for your academy, a typical distribution for 30 units is: 2×XS, 5×S, 8×M, 8×L, 5×XL, 2×2XL. Adjust based on what you know about your students.

6. MOQ and Turnaround Time

For custom sublimation rash guards, the MOQ at Nexpro Exports is 30 units per design. You can mix sizes within the same design, which makes it accessible for smaller academies.

• Sample production: 7–10 business days
• Bulk production (after sample approval): 15–20 business days
• Shipping to USA/UK/Australia: 5–10 days via DHL or FedEx
• Total timeline from order to delivery: Approximately 4–6 weeks

Plan your first order 6–8 weeks before the date you need them. This gives comfortable buffer for revisions, sample approval, and any unexpected delays.

7. IBJJF Rash Guard Rules for Competition

If your athletes compete in IBJJF events wearing no-gi divisions, rash guards must follow these rules:

• Long sleeve for black belt females (required)
• Color must match belt rank (white for white belts, blue for blue, etc.) or be all black
• Academy name or brand name is allowed on the rash guard
• No metal zippers or fasteners allowed

When ordering competition rash guards, specify IBJJF compliance and include the intended belt rank colors in your design brief.

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