Nearly everything visible on a yoga mat is customizable at FUJIAN SANFAN: length from 173 to 200 cm (68"–79"), width at 61, 80 or 122 cm (24" / 31" / 48"), thickness from 3 to 15 mm (1/8"–5/8"), Pantone-matched colours, two-tone double-layer builds, and logo by print, emboss, deboss or laser engraving. Cutting tolerance holds within ±1 mm on length and width and ±0.3 mm on thickness, and tooling for new sizes is made in-house, so a non-standard dimension rarely adds more than a few days to sampling. Three limits are honest ones: below 3 mm, print adhesion and cushioning both suffer; above 122 cm width, you need bespoke line setup; and photorealistic full-bleed print belongs on PU, not TPE. Send a one-page spec and you get a feasibility answer, a quote and a physical sample within 7 days.
Standard sizes, and why they are cheaper
The common format is 1830 × 610 mm (24"), with TPE thickness from 4 to 8 mm (5/32"–5/16") and up to 12 mm (1/2") for comfort lines. Standard sizes price lowest because the cutting patterns already exist and the line runs them without re-setup. Custom is not a premium product tier here; it is the same line with a different pattern, which is why the surcharge is usually smaller than buyers expect.
Width: standard, wide and double-wide
| Width | Who it suits | Commercial note |
|---|---|---|
| 61 cm (24") | Most solo practice | The default every competitor stocks |
| 80 cm (31") | Dynamic flows, broader shoulders | Easy line differentiation; few brands carry it |
| 122 cm (48") | Partner and family practice, studio rentals | Strong position for wellness brands |
Wide formats are one of the simplest ways to stand out in a catalogue, because most competitors only stock 61 cm (24"). We also produce lengths up to about 200 cm (79"); beyond that the constraint is the foaming and curing equipment, not the cutting, so ask before you design around an extreme format.
Thickness options
- 4–6 mm (5/32"–1/4"): portable, close-to-floor feel
- 6–8 mm (1/4"–5/16"): balanced cushion and stability
- 8–12 mm (5/16"–1/2"): extra joint comfort for sensitive knees
- 3 mm (1/8"): precision spec for travel mats, produced to order
Each thickness is its own production run, because foaming and curing parameters differ. Mixing thicknesses inside one order is possible at higher total volumes; plan each thickness as a separate line item when you request the quote.
Tolerances and tooling
Cutting tolerance holds within ±1 mm on length and width, ±0.3 mm on thickness. Tooling for a new width or an embossing plate is produced in-house, which is why a new size rarely adds more than a few days to sampling. Before anything is cut, we send a spec confirmation drawing so the physical result matches your artwork exactly. This step has saved more launches than any other: a drawing costs nothing to change, a 3,000-pcs batch does not.
Colour matching: where custom jobs go wrong
Colour is the most common custom failure, and it fails quietly: the mat looks right in the showroom photo and wrong on the shelf. Our workflow is deliberately unexciting. Start from your Pantone or a physical reference. Produce a small colour chip on the actual material — TPE tints differently than PU, so the chip is always on the real substrate, never a screen mock-up. You confirm the chip, we lock it against the golden sample, and the batch is checked against that reference at every QC station. One confirmation step, and an entire off-colour batch never happens.
Logo, print and branding
Custom Pantone colours, two-tone double-layer constructions, and logo by printing, embossing or laser engraving, on the mat surface and on packaging. For the trade-offs between logo methods — durability, cost, which surface each one suits — see the methods table in our private label launch guide.
Packaging and extras
Custom boxes, belly bands, barcodes, QR codes and inserts, so the product arrives shelf-ready under your brand rather than in a polybag with a sticker. Decide packaging before bulk starts; late packaging decisions cost more and protect less.
What customization cannot do
A few limits are worth knowing up front. Extreme sub-3 mm thickness loses cushioning and print adhesion — we produce 1830 × 610 × 3 mm (1/8") as a precision travel spec, but it is a specialist build, not a general-purpose mat. Widths beyond 122 cm need a bespoke line setup with a matching minimum. Photorealistic full-bleed print works far better on PU than on TPE foam. Within those bounds, almost any private-label look is achievable. When a request pushes past what survives daily use, we will say so plainly on day one instead of shipping a problem.
From spec sheet to sample
Send a one-page spec — material, size, colour, logo, packaging — and you get a quote and a physical sample, typically within 7 days. The sample you approve becomes the bulk reference, so what you feel in your hand is what your customer receives. That continuity is the whole point of custom work: no surprises between the sample and the shipment.
FAQ
What is the largest yoga mat you can make?
Double-wide mats around 122 cm (48") are routine, and lengths up to about 200 cm (79") are workable in standard production. Beyond that the limit is usually the foaming and curing equipment rather than the cutting. If you need an extreme format, ask the factory to confirm against its widest line before you design around it.
Do custom sizes need new tooling?
Usually no new tooling is needed for a different length or width in the same material and thickness — it is a cutting-pattern change. New tooling becomes relevant for unusual thicknesses, special edge profiles or embossed patterns. Ask which category your request falls into, because the answer drives both cost and MOQ.
Can thickness vary within one order?
Yes, but treat each thickness as its own production run, because foaming and curing parameters differ. Mixing thicknesses inside one order is normally accepted only at higher total volumes. Plan each thickness as a separate line item when you request a quote.
What is the MOQ for a custom size?
Higher than a standard size, because the line must be set up for a non-standard cutting pattern. FUJIAN SANFAN produces non-standard specifications including 1830 x 610 x 3 mm (1/8"); confirm the exact MOQ alongside the price when you request a quote.
Related reading
Where this fits in our own catalogue:
Non-standard dimensions? Send your length, width and thickness — we confirm tooling, feasibility and MOQ before you order. Get a quote.