Short answer: custom BJJ gi cost, when you buy factory-direct from Pakistan, typically starts at $22–$28 per gi for a pearl weave gi at 50 pieces, plus roughly $4–$6 for branding and $1–$2 for packing. After samples, freight, duty and VAT, most first orders land at around $32–$45 per gi delivered, depending on fabric, quantity, destination and how much customisation you add.
This guide breaks down every cost line so you can budget a custom gi order accurately — whether you are an academy owner ordering school gis or a founder launching a gi brand.
What Goes Into the Price of a Custom BJJ Gi?
The price a factory quotes is built from six main elements:
| Cost element | What drives it | Typical share of factory price |
|---|---|---|
| Jacket fabric | Weave type and GSM | Largest single cost |
| Pants fabric | Ripstop, drill cotton or pearl weave | Medium |
| Stitching and labour | Reinforcement points, triple stitching | Medium |
| Collar | EVA or rubber foam filling, rip-stop cover | Small |
| Branding | Embroidery, patches, woven labels, prints | Variable |
| Packing | Polybag, hang tag, box or gi bag | Small |
The fabric choice alone can move the price more than anything else, which is why the weave decision should come first.
Indicative Cost Breakdown for a First Order
Here is an indicative budget for a first order of 50 pearl weave gis shipped from Sialkot to the UK. Use it as a planning range and confirm exact figures in your quote.
| Cost line | Indicative estimate |
|---|---|
| Factory price per gi (pearl weave, 50 pcs) | $22–$28 |
| Branding per gi (collar label, chest patch, waistband print) | $4–$6 |
| Packing per gi (polybag + hang tag) | $1–$2 |
| Pre-production samples (one-time) | $80–$120 |
| Air freight for 50 gis to the UK | $280–$400 total |
| UK import duty | 0% on qualifying goods under the UK DCTS scheme |
| UK import VAT | 20% of the import value (usually reclaimable if VAT-registered) |
| Bank transfer fees | ~1–2% |
Spread across 50 gis, freight adds roughly $6–$8 per gi and samples about $2. That is how a $22–$28 factory price becomes a delivered cost in the mid-$30s to mid-$40s before VAT.
How Fabric and Weave Change the Price
| Weave | Typical GSM | Relative cost | Best for |
|---|---|---|---|
| Single weave | 350–450 | Lowest | Beginner and loaner gis |
| Ripstop | Lightest | Low | Lightweight and summer gis |
| Pearl weave | 450–550 | Mid (market standard) | Competition and everyday gis |
| Gold weave | 550–650 | Higher | Durable training gis |
| Double weave | 650–750 | Highest | Heavy drilling and grip training |
More fabric weight means more cotton, so heavier weaves cost more to make and more to ship. Read the BJJ gi fabric guide and lightweight vs heavyweight BJJ gi guide before you decide.
How Quantity Changes the Price
Unit price falls as quantity rises, because cutting, set-up and embroidery digitising costs are shared across more pieces.
| Order size | What to expect |
|---|---|
| 25 pcs (minimum OEM order) | Highest unit price; good for testing a design |
| 50–100 pcs | Noticeably lower unit price; most academy orders sit here |
| 100–500 pcs | Further reduction; free pre-production samples on orders above 100 pcs |
| 500+ pcs per SKU | Best pricing; full custom patterns become worthwhile |
Ordering one colour in a full size run is cheaper than splitting the same quantity across three colours, because each colour has its own fabric lot and dye batch.
Branding Costs: What Adds the Most
| Branding option | Cost impact |
|---|---|
| Woven collar label | Low |
| Embroidered chest or shoulder patch | Low to medium (depends on size and stitch count) |
| Rubber or silicone print on pants | Low to medium |
| Large back embroidery | Medium to high |
| Sublimated inner lining or panels | Medium to high |
| Custom printed box or gi bag | Medium; has its own minimums |
Embroidery is priced on stitch count, so a simple logo costs less than a detailed crest. See our custom BJJ patches and embroidery guide for ways to keep branding sharp without overspending.
Hidden Costs First-Time Buyers Miss
- Sample shipping — samples usually travel by express courier, which costs more per kilo than bulk freight
- Import VAT or sales tax — duty may be zero, but VAT or GST is still due at import in most countries
- Customs brokerage — courier clearance fees appear on the final invoice
- Size-run imbalance — ordering too many of one size leaves stock you cannot sell
- Photography and listings — if you are reselling, budget for product photos
- Currency movement — a quote in USD can cost more in GBP, EUR or AUD by payment day
Custom Gi Cost by Buyer Type
| Buyer | Typical order | Budget priorities |
|---|---|---|
| Academy owner | 25–100 school gis, one colour | Durable fabric, simple logo, mixed size run |
| New gi brand | 25–50 pcs per colour, 1–2 SKUs | Strong branding, IBJJF compliance, good packaging |
| Established brand or distributor | 200+ pcs per SKU | Lower unit price, consistent repeat quality |
| Tournament organiser | Event gis or medals-and-merch packs | Fixed deadline, clear sizing |
Academy owners can find more detail on our custom gear for BJJ academies page; brand founders should read how to start a BJJ gi brand.
How to Lower Your Cost per Gi Without Cutting Quality
- Pick the right weave for the job — a mid-weight pearl weave suits most academies; double weave is rarely needed for school gis
- Keep branding efficient — one strong chest patch and a woven collar label beat five small embroideries
- Order one colour first — add colours once you know what sells
- Plan a realistic size run — use our BJJ gi sizing chart and your past sales
- Use duty-free routes — Pakistan ships to the EU under GSP+ and to the UK under DCTS, so qualifying gis enter at 0% duty (read the duty-free import guide)
- Reorder the same spec — repeat orders skip sampling and run faster
Why Pakistani Factories Offer Better Value
Sialkot has more than a century of experience making combat sports equipment. Fabric mills, embroidery units and trims suppliers sit close together, which keeps both costs and lead times down. Factory-direct buying also removes the reseller margin — learn how to tell a real manufacturer from a reseller.
Frequently Asked Questions — Custom BJJ Gi Cost
Q: How much does it cost to make one custom BJJ gi?
A: Factories rarely produce a single branded gi because set-up costs are shared across an order. Our OEM programme starts at 25 pieces. At 50 pieces, a pearl weave gi costs around $22–$28 at the factory before branding, packing and freight.
Q: Why are some custom gis much cheaper than others?
A: Lower prices usually mean lighter fabric, fewer reinforcement points, thinner collars or no quality inspection. Compare GSM, stitching and collar construction, not just the price.
Q: Is shipping included in the gi price?
A: Usually not. Factory quotes are typically ex-works or FOB, with freight quoted separately by air or sea depending on volume and urgency.
Q: Do I pay import duty on gis from Pakistan?
A: Qualifying gis can enter the EU at 0% duty under GSP+ and the UK at 0% under DCTS, with the correct origin documents. Import VAT still applies. Rules differ in other countries, so check with your customs broker.
Q: How much should I budget for samples?
A: Plan around $80–$120 for pre-production samples plus express courier costs. On orders confirmed above 100 pieces, pre-production samples are free (buyer covers shipping).
Q: What payment terms are standard?
A: Standard terms are 50% deposit and 50% before shipment.
Q: Can I get a fixed quote before committing?
A: Yes. Send your weave, quantity, colours, sizes and logo files, and you will receive a written quote within 24 hours.
Get an Exact Price for Your Custom Gi
Every quote is built from your spec, so the fastest way to know your real cost is to ask. Onrox International has made custom gis and combat sports gear in Sialkot, Pakistan since 2010 and ships to more than 50 countries.
Get Your Custom Gi Quote → | OEM BJJ Gi Manufacturing → | Our BJJ Gi Range →
Related guide: for MOQs, lead times and bulk buying routes, see wholesale BJJ gis.