Custom Thermal Base-Layer Sets
ZipaSports manufactures custom thermal base-layer sets in Sialkot, Pakistan, with a minimum order of 20–25 pieces per design and 15–25 business day production. Academies running outdoor and winter scenario training order these as a matched top and legging set.
The inner face is brushed to hold warm air while the outer stays smooth so a combat trouser or training shirt slides over it. Flatlock seams keep the layer flat under clothing, and the top runs a high stand collar that can be pulled up in cold outdoor sessions. The back hem is extended so the top stays tucked through ground work.
Send your logo, colours and reference designs — or just an idea — and the design studio returns a free digital mockup within 24 hours. OEM and private-label orders ship with your own woven labels, size tags and branded packaging, applied in-house.
- MOQ 20–25 pcs per design
- Free 24h digital mockup
- Production 15–25 business days
- Ships worldwide from Sialkot
- Private-label ready
Thermal Base-Layer Sets Specifications & Options
| Fabric / materials | 240 GSM brushed poly-spandex, flatlock seamed |
|---|---|
| Fabric | 240 GSM brushed poly-spandex |
| Top | High stand collar, extended back hem |
| Legging | Flatlock seams, gusseted crotch |
| Decoration | Dye sublimation, screen printing, embroidery, DTF or heat transfer — matched to the design |
| Sizes | Adult XS–5XL, women's XS–4XL, youth sizes; fully custom size charts |
| Minimum order | 20–25 pieces per design; lower on request; no limit for sportswear brands |
| Sampling | Free digital mockup in 24 hours; physical sample 5–7 days at cost, credited on bulk order |
| Production time | 15–25 business days after design approval; express 7–12 days |
| Shipping | Worldwide — DHL/FedEx/UPS express 5–10 days; sea freight for bulk |
📏 Need measurements? See the sportswear size chart guide — or send your own size chart and we cut to it.
Thermal Base-Layer Sets Customisation Options
- Top and legging as a set or separately
- Stand collar, crew or quarter-zip neck
- Thumbhole cuffs for outdoor sessions
- Plain academy colours or sublimated panels
- Extended back hem length
- Mesh underarm panels for indoor use
- Women's and junior grading on the same block
- Woven academy label at the inner neck
- Fully custom patterns & made-to-spec designs — send a tech pack, sketch or sample
Thermal Base-Layer Sets — Frequently Asked Questions
What is the minimum order for custom thermal base-layer sets?
20–25 pieces per design. Lower quantities are possible on request, and there is no MOQ limit for sportswear brands and companies.
What are thermal base-layer sets made from?
240 GSM brushed poly-spandex, flatlock seamed. GRS-certified recycled fabric options are available on request.
How long does production take?
Bulk production takes 15–25 business days after design approval, with an express 7–12 day service at additional cost. A free digital mockup is delivered within 24 hours of your enquiry.
Can this be worn under combat trousers and a shirt?
Yes, that is the intended use. The smooth outer face is specifically chosen so an outer layer does not bind against it when a student moves on the ground.
How warm is a 240 GSM brushed layer?
Enough for outdoor sessions in cold conditions when worn under a shell. It is a base layer rather than insulation, so it works by trapping air against the skin, not by bulk.
Will the brushed face flatten over time?
Slowly, and mostly from fabric softener and hot drying. Wash cold without softener and line dry, and the nap stays effective for the life of the garment.
How much do custom thermal base-layer sets cost?
Pricing depends on fabric choice, order quantity, decoration and destination, so every order is quoted individually. Send your design and quantity on WhatsApp (+92 300 7019281) for a same-day quote and a free digital mockup within 24 hours.
Related resources
More Krav Maga products
