Manufacturer for Gyms, Dojos & Dance Studios
- Est. 2005 · Sialkot, Pakistan
- MOQ 20–25 pcs per design · no limit for brands
- Free 24h digital mockup
- Sample 5–7 days, credited on bulk
- Bulk 15–25 business days · express 7–12
- DHL/FedEx/UPS 5–10 days
- 🛡️ Free remake within 3 days
All pages in this section
Three kinds of order from one gym, dojo or studio
ZipaSports manufactures for gyms, dojos and dance studios from its factory in Sialkot, Pakistan: garments members buy at the front desk, garments coaches and instructors wear on the floor, and the technical kit a programme trains, fights or performs in, all under the business's own label from 20–25 pieces per design.
A gym is a different customer from a sports club. There is no season, so orders are smaller and more frequent; the range is broader, because one order might hold leggings, a hoodie, a cap and a coach polo; and the garments are sold or issued across the year rather than handed out once. The manufacturing answer is low minimums per design, private-label packing, and files kept on record so a reorder of one colourway takes an email.
Three programme guides sit below this hub: gyms, CrossFit boxes and yoga or pilates studios, BJJ, MMA and boxing gyms, and dance and cheer studios. Martial-arts academies running a student grading syllabus are also covered under academies and dojos.
Member merchandise: a first run that is deliberately small
A gym's first merchandise run at ZipaSports is 20–25 pieces per design in any size mix, which is enough to fill a front-desk rail without tying cash up in stock that has not sold.
Each artwork-and-garment combination is a design. A black tee and a white tee with the same logo are two designs; one hoodie colour cut in men's and women's fits is one design. Most gyms open with three or four: a tee, a hoodie, a pair of leggings or shorts and a cap, then add a bra or seamless set once the first run shows which sizes move.
Lower quantities are possible on request for a test colourway, and there is no MOQ limit for sportswear brands and companies, so a gym that has built its merchandise into a registered brand can reorder in whatever quantity the till suggests.
Everything is made to order. The free digital mockup within 24 hours lets you show members the design and take pre-orders before a single piece is cut, which is one way to fund a first run. The full range is under fitnesswear: tops, hoodies and jackets, compression and yoga, gym bags and accessories.
Fabrics and GSM for each garment
Every garment on a gym or studio order is cut in a fabric chosen for how it is used, and the weight is written in GSM on the order sheet so a reorder comes from the same cloth.
| Garment | Fabric options | Weight | Note |
|---|---|---|---|
| Leggings, bras, shorts | Nylon-spandex or polyester-spandex, 4-way stretch, 12–20% elastane | 240–300 GSM | Squat-proof at this weight; sublimation on the polyester option |
| Seamless sets | Nylon-elastane circular knit | 180–260 GSM | Knitted to shape; logo by heat transfer or embroidery |
| Tees and tanks | Polyester interlock with a moisture-wicking finish | 140–180 GSM | Sublimation or DTF |
| Hoodies and joggers | Cotton-polyester fleece; performance poly fleece for training | 280–350 GSM; 240–300 GSM | Embroidery, screen or puff print |
| Coach polos | Polyester piqué or poly-cotton piqué | 160–200 GSM; 200–240 GSM | Embroidered logo and role |
| Gi jackets and trousers | Pearl weave or single weave, cotton or poly-cotton; ripstop or twill trousers | 350–550 GSM; 8–12 oz | Embroidered chest logo and patches |
| Rash guards and spats | Polyester-spandex or nylon-spandex, flatlock seams | 180–220 GSM | Fully sublimated, rank colours in the print |
| Dance and cheer wear | 4-way stretch lycra and spandex; foil, velvet, mesh, sequin | 180–220 GSM | Rhinestone and crystal work in-house |
GRS-certified recycled polyester is available on request for studios that want it on the label; the fabric library lists every option with its GSM range.
Coach, instructor and front-desk wear
Staff wear is ordered as its own design in the same consignment as the merchandise, usually an embroidered polo or tee with the role on the sleeve or chest, so a member can find a coach on a busy floor.
The garment depends on the floor. Weight rooms and CrossFit boxes take a moisture-wicking tee or a polyester piqué polo; yoga and pilates studios lean towards a softer poly-cotton piqué or a fleece quarter-zip for front of house; BJJ and MMA gyms put instructors in a rash guard in the gym colour with a "Coach" or "Professor" mark; dance studios go for a branded warm-up jacket that teachers wear over class clothes.
Because staff sizes are known and stable, this is the design that most often runs at the lower end of the minimum or, on request, below it, while the merchandise designs carry the quantity. Role text is embroidered or heat-applied per piece, so "Head Coach" and "Instructor" can sit on the same design without splitting the run.
Plainer uniform pieces for reception and cleaning staff are covered under work polos and tees, and caps and beanies under caps and headwear.
Gis, rash guards and fight-team kit for dojos
A dojo or fight gym orders from ZipaSports the way an academy does: a house gi or rash guard in every student size, an instructor version, and a competition kit for the fight team, each with the gym's crest, patches and colours applied in-house.
Gi jackets are woven at 350–550 GSM in pearl weave or single weave, cotton or poly-cotton, with 8–12 oz ripstop or twill trousers, and the weight is recorded on the order so a student's second gi matches the first. Cotton shrinks in the wash, so ask for the finished measurements you need after washing to be written into the size specification; that specification is what the guarantee measures against.
Rash guards and spats are sublimated in polyester-spandex or nylon-spandex at 180–220 GSM with flatlock seams, so rank stripes, sponsor marks and the gym name are inside the print rather than applied on top. Boxing and Muay Thai programmes add satin shorts at 120–160 GSM.
Discipline pages: BJJ, MMA, boxing, Muay Thai, judo, karate, taekwondo and kickboxing; fabric detail in the BJJ gi fabric guide and rash guard guide.
Class uniforms and show costumes for dance and cheer studios
A dance studio orders two things from ZipaSports on different clocks: a class uniform that is reordered every intake, and show or competition costumes ordered once against a fixed date.
Class uniform is the steadier business: a studio-branded leotard, skirt, leggings and warm-up jacket in child through adult sizes, cut in 4-way stretch lycra at 180–220 GSM and embroidered or sublimated with the studio name, then reordered as new students join. Because the design is on file, a reorder of a few sizes is possible on request without going back to the full minimum.
Costumes are made to a show date. Sublimated bodices, mesh overlays, foil and velvet panels, sequin fabric and rhinestone or crystal embellishment are all applied in-house, and our in-house studio returns a mockup per routine within 24 hours of receiving the concept, for the studio owner to approve. Each routine's costume is one design, so the whole cast in every size counts against a single 20–25 piece minimum.
Cheer programmes order the same way, with practice wear, uniforms and accessories. Product ranges: leotards and bodysuits, costumes, skirts, leggings and tights, tops, jackets and warm-ups, cheerleading and dance bags.
Decoration: which method for which piece
Sublimation, embroidery, screen printing, DTF, puff print, heat transfer and rhinestone work all run in-house at ZipaSports, and a gym order normally uses three of them across one consignment: sublimation for polyester performance pieces, embroidery for polos, fleece and gis, and DTF or screen print for cotton-rich retail tees.
| Piece | Method | Why |
|---|---|---|
| Leggings, bras, rash guards | Dye sublimation | Colour is inside the polyester fibre; nothing to crack or peel under stretch |
| Hoodies, joggers, coach polos, gis | Multi-head embroidery | Raised logo that survives daily washing; gi patches stitched on |
| Retail tees, cotton-blend hoodies | DTF or screen print | Full-colour logo on cotton-rich fabric; screen print for large one-colour runs |
| Chest logos on fleece | Puff print | Raised matte finish for streetwear-style merchandise |
| Dance and cheer costumes | Rhinestone and crystal over a sublimated base | Stage sparkle on a base print that does not fade |
| Names, roles, rank text | Heat transfer or embroidery | Per-piece variation without splitting the design |
Logos are matched to a Pantone reference across methods, though thread and dye reproduce a colour differently and the mockup shows both. The choice is explained further in sublimation vs DTF vs embroidery.
Private label, reorder cadence and how we ship to you
Garments carry your label, not ours: woven neck labels, printed size tags, hang tags and branded polybags or boxes are produced with the order, so the piece on your rail reads as your gym's product. Details are on the private label and labels, tags and packaging pages.
We ship to your premises in one consignment, by DHL, FedEx or UPS in 5–10 days to the UK, USA, Canada, Australia and Europe, or by sea in 3–6 weeks for large runs. We do not post to individual members, hold stock for you or fulfil online orders on your behalf; if you sell online, stock is delivered to you or to a fulfilment partner you name, and dispatch happens from there.
Reorders follow your sales rather than a season: a first run of three or four designs, a repeat of the two that sold once the popular sizes run out, and a new colourway to keep the rail moving. Every reorder is produced from the approved file.
| Reorder type | Minimum | Lead time |
|---|---|---|
| New design or new colourway | 20–25 pieces per design | Mockup within 24 hours; bulk 15–25 business days |
| Repeat of an approved design | 20–25, lower on request | Approved files reused; 15–25 business days, express 7–12 |
| Established brand or company | No MOQ limit | Same production window |
Timing, Quality Guarantee and what to send us
Quality Guarantee: if any garment arrives with a manufacturing defect, we remake it free of charge — the remake goes into production within 3 days of your report.
For a gym selling merchandise, that means a misprinted hoodie or an open seam on a legging is remade and shipped at no charge, or credited, after you send photos and the order reference within 7 days of delivery; we confirm within 24 hours in business hours. Dye-lot shade, measurements within ±1–1.5 cm of the size chart and a member choosing the wrong size are not defects, and made-to-order pieces carrying your label cannot be returned for change of mind. Full wording: Quality Guarantee and return policy.
| What to send | Detail |
|---|---|
| Logo | Vector file (AI, EPS, PDF) or a clear image; the studio redraws if needed |
| Garment list | Each piece with fabric preference, colour or Pantone reference, and decoration method |
| Sizes | Quantity per size per design; adult, women's and youth ranges as needed |
| Labels and packing | Woven label artwork, size tag text, hang tag, polybag or box |
| Date and address | Launch, grading or show date; delivery address and country |
Send it to zipasports@gmail.com or WhatsApp +92 300 7019281. A mockup comes back within 24 hours, and a physical sample follows in 5–7 days at sample cost, credited against the bulk order.
Frequently Asked Questions
Can our gym sell leggings and hoodies under our own brand name?
Yes, ZipaSports produces private-label gym leggings and hoodies from 20–25 pieces per design with your woven neck label, printed size tags, hang tags and branded polybags, so nothing on the garment names the factory. Once your merchandise is an established brand or company, the no-MOQ-limit policy applies.
What is the minimum order for gym merchandise?
The minimum order for gym merchandise at ZipaSports is 20–25 pieces per design, in any mix of sizes. Lower quantities are possible on request for a test colourway or a staff run, and there is no MOQ limit for sportswear brands and companies. Each artwork-and-garment combination counts as one design.
Do you drop-ship to our members or fulfil our online shop?
No, ZipaSports ships the finished order in one consignment to your gym, studio or a fulfilment address you name, by DHL, FedEx or UPS in 5–10 days. We do not post to individual members, hold stock or pick and pack consumer orders; dispatch to members is handled on your side.
Can you make a BJJ gi with our academy logo embroidered?
Yes, ZipaSports makes BJJ gis in pearl weave or single weave cotton or poly-cotton at 350–550 GSM with 8–12 oz ripstop or twill trousers, and the academy crest, shoulder and trouser patches are embroidered in-house at the Sialkot factory. Student, instructor and competition versions can share one order.
What gi weight should a dojo order for students?
A dojo chooses a student gi from the 350–550 GSM range by use: the lighter end for daily training, children's classes and warm gyms, the heavier end where durability through years of washing matters more than weight. State the finished measurements you need after washing and they go into the size specification.
Can coach polos and member tees go in the same order?
Yes, coach polos and member tees can go in one order: each garment-and-artwork combination is its own design with its own 20–25 piece minimum, but they ship together in one consignment. Staff designs are often the ones run at the low end of the minimum, or below it on request, while the retail designs carry the quantity.
How often can we reorder, and will the colours match?
A gym or studio can reorder from ZipaSports at any time, because there is no fixed reorder cadence. Approved print files, Pantone references and embroidery files are kept on record, so a repeat comes from the same specification. Minor shade variation between dye lots is normal on sublimated fabric and is not treated as a defect.
Can a dance studio order costumes in children's and adult sizes together?
Yes, one routine's costume is one design, so every dancer from the youngest class to adult counts against a single 20–25 piece minimum. Sublimated bases, mesh, foil, velvet and rhinestone embellishment are applied in-house, and a mockup per routine is returned within 24 hours.
How long from mockup to delivery at our gym in the UK or USA?
From mockup to delivery, allow a mockup within 24 hours, an optional sample in 5–7 days, bulk production of 15–25 business days after approval, then 5–10 days by DHL, FedEx or UPS to the UK, USA, Canada, Australia or Europe. Express production in 7–12 days is available at additional cost for a fixed launch or grading date.
What happens if a piece arrives with a print fault?
Free remake within 3 days on any manufacturing defect. Send photos and the order reference on WhatsApp or email within 7 days of delivery; we confirm within 24 hours in business hours, remake the affected pieces and ship them at no charge, or credit them if you prefer.