Why Our Rash Guards Feel Different (Because They Are)

How a Tesshin Rashguard is Made: The Pursuit of Better

Most brands begin their rashguard creation with a template — an existing product reused endlessly, swapping only the artwork on top. At Tesshin the process begins much earlier, long before ink touches fabric.
Because to build something worthy of discipline, you start from zero.

Rebuilding the Rashguard From the Ground Up

When we designed our first piece, we didn’t ask “What should it look like?”
We asked: “How should it function?”

Instead of reusing the standardized cut like everybody else does, we deconstructed the rashguard into its most fundamental parts and rebuilt it panel by panel. Every curve, seam, and angle was engineered intentionally — no guesswork, no generic templates, no shortcuts.

Each panel serves a specific physiological or performance purpose:

• Breathability panels to keep you cool under pressure
• Protection zones over high-friction, impact-prone areas
• Temperature-optimized fabric that insulate or ventilate where needed
• Moisture-wicking fibers that dry fast and stay light
• Strategic mesh ventilation for increased airflow
• Compression-tuned sections for muscle support and ergonomics
• Silicone-lined grip zones to anchor your gear during scrambles

The result: a 10-panel system—nearly double the industry standard—where each piece works like part of an engineered machine.

Experimenting With Materials Until It Was Right

Not all fabric is created equal, and not all parts of your body need the same support. We tested dozens of material blends, exploring varying densities, weaves, and fiber compositions until each panel had its ideal performance profile.

• Lighter fabrics for airflow
• Denser blends for abrasion resistance
• Stretch-optimized textiles in mobility zones
• Cooling weaves in heat-accumulating regions

Rather than force one fabric to do everything, we let each fabric do what it does best.

Bringing Artwork to Life With Italian Sublimation Ink

After each panel is engineered, the art comes next.

We print using premium Italian sublimation ink, a high-end method where the ink turns directly into gas and infuses into the fibers at high heat. The result is:

• Deep, non-fading color
• Durable designs that never crack or peel
• Artwork that is weightless and smooth against the skin

Sublimation isn’t surface-level printing; it becomes one with the fabric, making it the gold standard for high-performance combat gear.

Laser Cutting: Precision Down to the Millimeter

Once printed, every panel is cut using industrial laser cutters. This ensures:

• Perfect consistency across every unit
• Clean, sealed edges that don't fraying
• Seam accuracy that traditional cutting simply can’t match

If we engineered each panel with intention, the cut must honor that precision.

Reinforced Flatlock Stitching on Japanese Machines

The panels are assembled using reinforced flatlock stitching—the gold standard for combat sports apparel. Flatlock stitching:

• Lays flat against the skin to prevent irritation
• Distributes tension evenly for long-term durability
• Handles stress from pulling, twisting, and grappling

All stitching is performed on premium Japanese sewing machines, operated by trained technicians who specialize in combat sportswear. Every seam is placed with intention, overseen by highly experienced hands.

Human Inspection, Every Time

Before a Tesshin rashguard reaches its packaging, it passes through a full manual inspection.
A real person checks:

• Stitch integrity
• Panel alignment
• Color consistency
• Tactile smoothness
• Print accuracy

Only when it meets our standard—our real standard, not the industry’s—does it get sealed and sent to its new owner.

Relentless Improvement: The Tesshin Standard

We’ve partnered with multiple manufacturers and kept only those who can match our vision for precision and discipline. And even then, we never stop refining.

We’re constantly evaluating:

• Better equipment
• Better materials
• Better artisans
• Better processes
• Better partners

Because discipline means never assuming you’ve arrived.
It means rebuilding, rethinking, refining—again and again.