Brazilian Jiu-Jitsu and grappling gear manufacturer for combat sports brands

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BJJ gear has a construction problem most sportswear doesn't: a gi has to survive constant gripping, pulling, and mat friction while staying within weave and weight standards competitors expect. Blue Star Manufacturing produces GI and no-gi collections, grappling apparel, belts, protective wear, and academy merchandise for combat sports brands, academies, and importers across the USA, UK, and Europe, including private label production for brands that want the range made and delivered under their own name.

What we manufacture for BJJ and grappling brands

Our range covers what an academy or grappling brand typically needs: gis built to standard weave weights for training and competition, no-gi rash guards and spats for grip-free grappling, belts for rank progression, protective wear for sparring, and academy merchandise for branded gear beyond the mat. GI construction depends heavily on weave type and reinforcement at stress points like the collar and knees, since that's where a gi wears out first. We produce from the buyer's own tech pack and sizing rather than a stock catalog.

From your design to a finished sample

Most orders start with a reference gi, a design file, or a full spec sheet. We build a sample from that, confirm fabric weight, weave, fit, and stitching, and get it signed off before bulk production begins. Academy patches, belt embroidery, or a private label brand's own tags and trims are applied at the sample stage, so what ships in bulk matches exactly what was approved.

Consistency across the order

A gi or belt that holds up correctly as a sample has to perform the same way across a full production run, and again if an academy or brand reorders the following season. Cutting and stitching stay consistent, seams get checked at each stage, and fabric batches are tracked so weight and quality don't drift between deliveries.

If you have a design, a reference gi, or a spec sheet ready, send it over, and we'll walk you through sampling and timelines for your BJJ and grappling range.