How Muay Thai shorts are made, step by step in our factory
- Boxvilo has made custom fightwear in its own factory in China since 2019, with a team of 173 people.
- A custom fight short passes through five stations: cutting, decoration, sewing, finishing and a visual check before packing.
- We decorate by multi-head embroidery, laser-cut appliqué and sublimation printing, and pick the method that suits each design.
A custom fight short starts as flat panels cut from satin or printed fabric. Names and logos are then embroidered, laser-cut from metallic fabric or printed into the cloth. Sewers join the panels, fit the waistband and add binding or fringe, and every piece is checked by eye before packing.
In this 54-second video:
- 0:07 Multi-head embroidery
- 0:20 Laser-cut appliqué
- 0:30 Sublimation panels
- 0:35 Sewing and binding
- 0:49 Finished stock
Step 1 - How are the panels cut?
Each pair starts as flat pattern pieces: two legs, side panels and a waistband. Plain satin is cut in stacks. Printed fabric is cut by laser along the printed outline, so the artwork lines up exactly at the seams.
Step 2 - How are names and logos stitched?
Names, flags and logos are stitched on multi-head embroidery machines, which sew the same design on many panels at once. That is how a team order gets identical logos on every pair. Each panel can still carry a different fighter's name in the same run.
Step 3 - What is laser-cut appliqué?
Appliqué is a shape cut from a second fabric and stitched onto the shorts. We cut metallic and holographic fabric by laser, which gives clean edges on small letters and detailed shapes such as dragons, then stitch the edges down.
Step 4 - How are the shorts sewn and finished?
Sewers join the leg panels, attach the wide elastic waistband and finish the edges with satin binding. Fringe is sewn into the leg seam, not glued. Hoods, zips and linings are added on the same sewing line for robes and vests.
Robes get the same treatment at a larger scale. See our boxing robes with embroidered backs and satin linings.
Step 5 - What do you check before packing?
Every piece gets a visual check before packing. We look at the stitching, the binding and fringe, the embroidery and appliqué edges, the color against the approved sample, and any stains or loose threads. It is a visual check by our own team, not a lab test.
What we don't test
We don't run lab tests such as color-fastness or seam-strength reports on every order. If your market or retailer needs a lab report, tell us when you order and we'll arrange third-party testing at your cost.
Which decoration should you choose?
Choose embroidery for names, gym logos and Thai script on satin, because it looks raised and premium. Choose sublimation for full-color artwork across the whole short, ideally on a light base. Choose laser-cut appliqué when you want big shiny letters or shapes that catch the ring lights.
| Method | Best for | Trade-off |
|---|---|---|
| Embroidery | Names, logos, Thai script | Adds stiffness; very large areas can feel heavy |
| Sublimation | Full-color, photo or gradient designs | Works best on light polyester; not for dark bases |
| Laser-cut appliqué | Big metallic letters, dragons, flags | Edges need careful stitching to stay flat |
| Heat transfer | Simple logos on training shorts | Less durable than the other three |
Every method is available on our satin, fringe and petal-cut fight shorts.
Still deciding? See when to pick embroidery or sublimation.
Which fabrics do you work with?
Most fight shorts are satin, which is smooth, shiny and takes embroidery well. We also use quick-dry polyester for training wear, full sequin fabric for walkouts, and holographic, metallic and brocade fabrics for trims and statement pieces.
| Fabric | Typical use |
|---|---|
| Satin | Fight shorts, trunks, robes |
| Quick-dry polyester | Training shorts and shirts |
| Sequin | Walkout jackets, vests, trunks |
| Holographic and metallic | Appliqué, side panels, trims |
| Brocade (jacquard satin) | Side panels, robes |
Brocade
Jacquard satin with a woven pattern, finished here with gold binding and fringe.
Holographic
Shifts color under ring lights. Used for full shorts, side panels and appliqué.
Sequin
Full sequin fabric for walkout sets, vests and statement trunks.
Who makes your order?
Your order is made by our own team of 173 people, in the factory we have run since 2019. Cutting, embroidery, printing and sewing all happen under one roof, so your order is never passed to another workshop.
One account manager follows each order from mockup to shipping. Read the custom order process, step by step, or meet the team behind Boxvilo.
Questions buyers ask about our craft
Will embroidery fray?
Dense embroidery on satin is stitched tight and sits raised on the fabric. Wash shorts inside out in cold water and skip the dryer to keep the stitching flat.
Will sublimation fade?
Sublimation ink bonds into the polyester fibers rather than sitting on top. Bright colors stay sharpest on a light base fabric.
Is the fringe glued on?
No. Fringe is sewn into the leg seam.
Pick your fabric and decoration
We reply by email within 2 days with a mockup and a price.