Professional Martial Arts & Gym Flooring Manufacturer Since 1981

Professional Sport Mats & Martial Arts Flooring Manufacturer

Direct global manufacturer of professional high-density sport mats and athletic flooring systems - 1m×1m Taekwondo interlocking puzzle mats with authentic five-line basketweave texture, commercial multi-color EVA gym floor tiles, heavy-duty EVA + rubber composite mats, portable XPE roll-up wrestling mats, and 1m×2m IJF standard Judo tatami mats. Engineered for martial arts dojos, commercial gyms, MMA academies, and tournament venues with high impact shock absorption, zero formamide, and anti-slip stability.

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250,000㎡

Global production area

120+

Foaming & CNC mold press lines

Manufacturing bases (CN / VN / ID)

40+ Yrs

Sports flooring engineering

About Firefox Foam Sport Mats Division

Global Martial Arts Dojo & Fitness Flooring OEM / ODM Supplier

Quanzhou Firefox New Material Co., Ltd. is an established manufacturer of athletic flooring and martial arts training mats. Operating modern manufacturing campuses across China, Vietnam, and Indonesia, we provide Tier-1 sports brands, national federations, commercial gym chains, and martial arts academies with vertically integrated capabilities - from custom polymer compounding, high-pressure hydraulic molding, and precision CNC die-cutting to thermal lamination and SATRA/EN standard shock absorption testing.

40+ Years Sports Heritage

Continuous innovation in high-density polymer compounding, impact cushioning, and sports safety since 1981.

Full Sport Mat Matrix

Integrated manufacturing across Taekwondo puzzle mats, EVA gym tiles, EVA+rubber tiles, XPE roll mats, and Judo tatami.

Certified Shock Absorption

Compliant with EN 12503, EN 1177, and ASTM F1292 standards for critical fall height protection and joint safety.

100% Non-Toxic & Zero VOC

Formamide tested strictly <10 ppm, certified free of phthalates and heavy metals per EU REACH SVHC and RoHS 3.

Comprehensive Sport Mat Product Matrix

Complete Line of Martial Arts, Fitness & Tournament Flooring Systems

Firefox Foam manufactures a complete matrix of professional sport mats engineered for high impact absorption, joint protection, thermal insulation, and extreme wear resistance. Every mat is manufactured using precision molds with strict quality control from raw polymer compounding to final packaging.

1. Taekwondo Interlocking Puzzle Mats (1m×1m)

Reversible dual-color high-density EVA puzzle mats with authentic five-line basketweave anti-slip surface texture. Standard 1m×1m (100×100cm) square dimensions in 20mm, 25mm, 30mm, and 40mm thicknesses with precision CNC interlocking teeth and detachable border strips for seamless dojo assembly.

2. Commercial High-Density EVA Gym Floor Mats

Heavy-duty interlocking and straight-edge EVA workout tiles designed for commercial fitness clubs, cross-training boxes, and home gyms. Features high shock damping, acoustic deadening under free weights, and multi-color customized surface patterns.

3. Heavy-Duty EVA + Rubber Composite Mats

Dual-layer hybrid flooring combining a 3mm–5mm high-density EPDM/SBR speckled rubber wear top with a 15mm–20mm shock-absorbing closed-cell EVA foam base. Delivers superior barbell drop resistance with lightweight handling and interlocking portability.

4. Portable XPE Roll-Up Wrestling & MMA Mats

Lightweight tournament roll mats featuring cross-linked closed-cell XPE foam with segmented flex-slit backing and heavy-duty 26oz tatami or smooth PVC vinyl top. Rapid 2-minute roll-out setup for wrestling, gymnastics, BJJ, and law enforcement training.

5. IJF Standard Judo Tatami Mats (1m×2m)

Official 1m×2m (100×200cm) and 1m×1m competition Judo tatami mats constructed with high-density compressed PU/PE sponge core, traditional non-slip straw-textured heavy vinyl surface, and anti-skid honeycomb rubber waffle backing.

Engineering Parameters

Technical Specifications & Material Property Data Sheet

All sport mat products undergo rigorous batch testing for density, hardness, impact attenuation, tensile strength, and chemical safety to ensure consistent tournament performance and long service life.

Performance Property	Taekwondo Mats	EVA Gym Mats	EVA + Rubber Mats	XPE Roll-Up Mats	Judo Tatami Mats
Base Core Material	Closed-Cell EVA Foam	High-Density EVA	EPDM Rubber + EVA Base	Cross-Linked XPE Foam	Compressed PU / PE Foam
Surface Texture	Five-Line Basketweave / T-Pattern	Cross / Checker / Smooth	Speckled EPDM / Fine Grain	Smooth Vinyl / Tatami PVC	Traditional Tatami Straw Weave
Standard Dimensions	1m × 1m (100 × 100 cm)	1m × 1m / 50 × 50 cm	1m × 1m / 50 × 50 cm	1.5m / 1.8m width × 6m–15m	1m × 2m (100 × 200 cm) / 1m × 1m
Standard Thickness	20mm, 25mm, 30mm, 40mm	15mm, 20mm, 25mm, 30mm	15mm, 20mm, 25mm	30mm, 40mm, 50mm	40mm, 50mm (±1mm)
Core Density	90 – 120 kg/m³	80 – 110 kg/m³	Top: 1100 kg/m³ / Base: 110 kg/m³	33 – 45 kg/m³ (XPE)	230 – 270 kg/m³ (High Rebound)
Hardness (Shore C/A)	35° – 45° Shore C	38° – 50° Shore C	Top: 65° Shore A / Base: 45° C	30° – 38° Shore C	Firm / Tournament Spec
Shock Absorption Rate	≥ 45% (EN 12503-3)	≥ 40%	≥ 55% (Dead-Blow Damping)	≥ 60% (High Impact Drop)	≥ 70% (IJF Fall Protection)
Formamide Content	< 10 ppm (EN 71-3 / REACH)	< 10 ppm	< 10 ppm (VOC Compliant)	0 ppm (Cross-Linked XPE)	< 10 ppm (Non-Toxic Adhesive)

Selection Guide

Sport Mat Material Matrix & Application Comparison

Compare our core sports flooring technologies to select the optimal balance of impact protection, portability, footprint, and maintenance for your facility.

Evaluation Factor	EVA Puzzle Mats	EVA + Rubber Composite	XPE Roll-Up Mats	Judo Tatami Mats
Primary Applications	Taekwondo, Karate, Kickboxing, Kids Martial Arts	Free Weight Gyms, CrossFit, Strength Zones	Wrestling, MMA, BJJ, Gymnastics, Cheerleading	Judo, Aikido, Jujitsu, Throwing Sports
Installation Speed	Fast (Interlocking DIY teeth)	Fast (Interlocking / Loose-lay)	Instant (Roll-out & Mat Tape)	Modular (Frame / Anti-skid base)
Weight & Portability	Ultra-light (approx. 2.2 kg/pc for 25mm)	Medium (approx. 5.5 kg/pc for 20mm)	Lightweight roll (one-person setup)	Heavy-duty tournament (approx. 18 kg/pc)
Surface Grip & Friction	High barefoot grip (Basketweave)	Extreme shoe traction (Tire Rubber)	Non-abrasive smooth / Tatami vinyl	Traditional tatami straw weave grip
Impact / Throw Cushioning	Medium-High (Footwork & Light Falls)	High (Barbell & Dumbbell Impact)	High (Throws, Takedowns & Flips)	Maximum (Heavy Body Throws & Slams)
Cleaning & Maintenance	Mop with neutral detergent	Vacuum & damp mop	Wipe down vinyl with disinfectant	Sanitize vinyl surface easily

Precision Manufacturing

8-Step Vertically Integrated Sport Mat Production Workflow

From high-purity virgin polymer compounding to multi-point dimensional laser inspection, every manufacturing phase is tightly controlled in-house.

Polymer Compounding

High-grade virgin EVA / LDPE resin blending with odorless blowing agents and color masterbatches.

Internal Banbury Mixing

High-shear internal mixing ensures homogeneous additive dispersion and zero agglomeration.

High-Tonnage Press Foaming

Hydraulic compression foaming under controlled temperature and pressure creates uniform closed-cell bubbles.

Curing & Aging Chamber

Controlled degassing and thermal stabilization to eliminate residual VOCs and shrinkage.

Thermal Lamination

Flame or solvent-free adhesive bonding of multi-color EVA layers, rubber skins, or vinyl covers.

Precision CNC Die Cutting

Automatic CNC die-cutting for micro-tolerance interlocking puzzle teeth and clean borders.

Quality & Safety Testing

Continuous testing for shore hardness, density, tensile strength, and zero-formamide compliance.

Export Shrink Packaging

Corner protectors, high-clarity shrink wrapping, custom barcode labeling, and palletizing.

Customization & Private Label

End-to-End Sport Mat OEM / ODM Custom Capabilities

Firefox Foam provides international martial arts brands, gym equipment suppliers, and sports tournament organizers with turnkey custom engineering services:

Custom Surface Textures: Five-line basketweave, T-pattern, diamond plate, wood grain, tatami straw weave, smooth vinyl, or bespoke logo embossing.
Dual & Multi-Color Formulations: Reversible red/blue, black/grey, yellow/blue, wood/black, or exact Pantone matching for brand alignment.
Laser & Silk-Screen Logo Printing: Permanent UV ink printing or thermo-pressed brand logos and tournament ring markings.
Custom Dimensions & Interlocks: Tailored puzzle tooth geometries compatible with existing customer molds or proprietary systems.

Quality Assurance

In-House Mechanical & Safety Testing Laboratory

Our ISO 9001-certified testing facility performs standardized quality testing on every production lot:

Critical Fall Height (CFH): Dynamic drop impact testing per EN 1177 and ASTM F1292.
Anti-Slip Friction Coefficient: Dry and wet pendulum slip resistance per EN 13036-4.
Tensile & Tear Resistance: Interlocking tooth pull-out force and seam shear testing.
Chemical & Heavy Metal Screening: On-site GC-MS screening for formamide (<10 ppm), phthalates, and SVHCs.

International Compliance

Certified to Global Sports Safety & Environmental Standards

Our sport mats are tested and verified by independent accredited laboratories (SGS, TÜV Rheinland, Intertek) to satisfy the strictest international import and competition regulations.

EN 12503

Sports Mats European Norm

Certified for shock absorption, base friction, and top surface friction for martial arts dojos.

REACH SVHC

EU Chemical Safety

100% compliant with EU REACH Annex XVII and 240+ Substances of Very High Concern.

FORMAMIDE

Zero Formamide Standard

Strictly controlled <10 ppm according to French Decree 2010-1664 and European toy safety.

ISO 9001 / 14001

Management Systems

Fully certified quality and environmental management across China and Southeast Asia plants.

Logistics & Supply Chain

Optimized Container Loading & Export Packaging Solutions

We maximize freight efficiency and protect your goods during multi-modal ocean and rail transit with robust packaging methods.

Product Category	Packaging Method	Pieces per Carton / Bundle	20ft GP Container Load	40ft HQ Container Load
Taekwondo Mats (20mm)	Heavy polybag / Corrugated Carton	10 pcs / carton	Approx. 1,200 pcs	Approx. 2,900 pcs
Taekwondo Mats (25mm)	Heavy polybag / Corrugated Carton	8 pcs / carton	Approx. 950 pcs	Approx. 2,300 pcs
Taekwondo Mats (40mm)	Heavy polybag / Corrugated Carton	5 pcs / carton	Approx. 600 pcs	Approx. 1,450 pcs
EVA + Rubber Composite (20mm)	Palletized with shrink film	4 pcs / pack on pallets	Approx. 800 pcs	Approx. 1,900 pcs
Judo Tatami Mats (1m×2m × 40mm)	Edge corner guards + woven bags	20 pcs / wooden pallet	Approx. 260 pcs (13 pallets)	Approx. 600 pcs (30 pallets)
XPE Roll-Up Mats (1.5m × 10m)	Individual heavy-duty vinyl storage bag	1 roll / bag	Approx. 120 rolls	Approx. 280 rolls

Procurement Checklist

What to Specify When Requesting a Sport Mat Quotation

To receive an accurate factory quotation and technical data sheet within 24 hours, please include the following key specifications in your inquiry:

Product Type & Core

Taekwondo puzzle mat, EVA gym tile, EVA+rubber, XPE roll mat, or Judo tatami.

Dimensions & Thickness

Mat dimensions (1m×1m, 1m×2m, custom) and exact thickness (20mm, 25mm, 40mm, 50mm).

Color & Surface Texture

Reversible red/blue, solid black, wood grain, basketweave, T-pattern, or tatami texture.

Target Volume & Port

Estimated order quantity (sqm or pieces) and your destination seaport for CIF/DDP calculation.

Technical & Commercial FAQ

Frequently Asked Questions About Sport Mats & Athletic Flooring

Find fast answers to common procurement questions regarding material grades, safety certifications, custom tooling, MOQ, and international delivery.

1. What are the key differences between Taekwondo puzzle mats and Judo tatami mats?

Taekwondo mats are modular 1m×1m closed-cell EVA interlocking puzzle tiles with five-line basketweave or T-pattern surfaces designed for fast footwork, pivot traction, and light falls (20mm–25mm thickness). Judo tatami mats are larger 1m×2m high-density compressed PU/PE sponge slabs (40mm–50mm) covered with heavy-duty PVC vinyl tatami straw weave and rubber honeycomb anti-skid bases, engineered specifically for high impact drop energy absorption from full-body throws.

2. How do you ensure your EVA sport mats are 100% non-toxic and free of formamide?

We utilize high-purity virgin EVA copolymers and advanced odorless chemical blowing formulations combined with an extended thermal vacuum degassing curing phase. Every batch is tested in-house and validated by SGS/TÜV to ensure formamide levels are strictly below 10 ppm, fully complying with French Decree 2010-1664 and EU REACH standards.

3. What is the standard surface texture of your 1m×1m Taekwondo mats?

Our standard flagship Taekwondo mat features an authentic five-line basketweave (五线席纹) pattern consisting of alternating horizontal and vertical groups of five raised parallel ribs. This geometry provides 360-degree multi-directional anti-slip grip for barefoot martial artists while preventing skin burn during rapid slides.

4. What thicknesses are recommended for different martial arts disciplines?

Recommended thicknesses: Karate, Taekwondo & Stand-up Striking: 20mm–25mm; Kickboxing, Boxing & Aerobics: 25mm–30mm; Brazilian Jiu-Jitsu (BJJ), MMA & Grappling: 30mm–40mm; Judo, Aikido, Sambo & Heavy Throwing: 40mm–50mm (Judo Tatami).

5. Can you produce dual-color reversible mats?

Yes. We specialize in co-molded and thermally laminated dual-color reversible puzzle mats (e.g. Red/Blue, Black/Grey, Blue/Yellow, Red/Black). Both faces feature identical interlocking teeth and surface textures, allowing dojo owners to flip tiles to define competition ring borders or sparring zones.

6. How many border strips are included with each interlocking mat?

Each standard 1m×1m puzzle mat is supplied with 2 detachable straight-edge border strips. This allows you to finish both corner tiles and perimeter wall edges with clean, gap-free boundaries without trimming teeth manually.

7. What are the advantages of EVA + Rubber composite mats over 100% solid rubber tiles?

Solid rubber tiles are extremely heavy (15–20 kg per sqm) and expensive to ship. Our EVA+Rubber composite pairs a 3mm–5mm durable EPDM/SBR speckled rubber surface with a 15mm–20mm high-density EVA shock-absorbing foam base. This reduces total mat weight by over 50%, improves acoustic deadening under dropped weights, lowers shipping container costs, and retains convenient puzzle interlocking assembly.

8. How do XPE roll-up mats connect together for large gym floors?

XPE roll-up mats are connected using heavy-duty 4-inch (10cm) matte PVC mat tape or Velcro fastening systems along the seams. Mat tape creates a seamless, watertight competition surface that prevents dirt accumulation and eliminates tripping hazards during wrestling and grappling tournaments.

9. What is the standard lifespan of Firefox Foam sport mats in commercial dojos?

Under standard indoor commercial training conditions with regular maintenance, our high-density EVA puzzle mats deliver a service life of 5–8 years. Our heavy-duty Judo tatami mats and XPE roll-up mats typically deliver 7–10+ years of high-volume competition use without foam cell collapse.

10. What is your Minimum Order Quantity (MOQ) for custom colors or logos?

For standard inventory colors (Red/Blue, Black/Grey, Wood), our MOQ is 100 pieces (100 sqm). For custom Pantone color matching or custom embossed logos, the typical MOQ is 300–500 pieces per color/thickness depending on production run requirements.

11. Can you print our brand logo directly onto the mats?

Yes. We offer high-resolution UV digital printing, silk-screen printing with wear-resistant polyurethane inks, and permanent heat-embossing of custom brand logos, center ring circles, and sponsor graphics onto both EVA puzzle mats and vinyl tatami covers.

12. How should EVA sport mats and Judo tatami be cleaned and maintained?

Clean daily using a damp mop or microfiber cloth with warm water and a neutral disinfectant (pH 7). Avoid harsh acidic solvents, bleach, or abrasive scrubbing pads. Allow the floor to air dry completely before training sessions to maintain maximum coefficient of friction.

13. Are your sport mats suitable for outdoor use?

Our sport mats are primarily engineered for indoor athletic facilities. While closed-cell EVA and XPE foams are 100% waterproof and mildew-resistant, prolonged exposure to direct outdoor sunlight and high temperatures may cause UV fading and thermal expansion. For temporary outdoor events, mats can be used and stored indoors afterwards.

14. What international quality certifications do your sport mats hold?

Our sport mats are tested and certified to EN 12503 (Sports Mats), EN 1177 / ASTM F1292 (Critical Fall Height impact attenuation), EN 71-3 / French Decree 2010-1664 (Formamide <10 ppm), EU REACH SVHC, RoHS 3, and ISO 9001 quality management standards.

15. What is the typical production lead time for a full container order?

Standard production lead time for a 20ft or 40ft HQ container (approx. 1,500–3,000 mats) is 15–20 business days from deposit and artwork approval. Expedited production is available for urgent tournament deadlines.

16. How do you protect mats from deformation and edge damage during ocean transit?

Mats are bundled with heavy-duty corner protectors, wrapped in thick moisture-proof PE shrink film, and packed into heavy 5-ply double-wall export corrugated master cartons or strapped securely onto reinforced wooden pallets. Container loading is inspected to prevent crush loads.

17. Do you provide free physical sample swatches before mass production?

Yes. We provide free sample swatches (mini-tiles showing thickness, hardness, and surface texture) for qualified commercial buyers and distributors. Courier express freight (DHL/FedEx/UPS) is paid by the buyer and credited back against the first commercial order.

18. Can you supply full martial arts dojo turnkey floor plans?

Yes. Our engineering team can review your dojo or gym CAD floor plan and calculate exact mat quantities, color layouts, safety warning border perimeters, wall padding pads, and custom corner cuts to ensure zero material waste.

19. Are the puzzle teeth compatible with other brands of mats?

We utilize standardized universal interlocking tooth molds. If you need compatibility with an existing dojo installation, you can ship us one sample tile or high-precision engineering drawings, and our CNC mold workshop can machine matching custom interlock dies.

20. What payment terms and trade incoterms do you accept?

We support FOB (Xiamen / Ningbo / Shenzhen / Ho Chi Minh / Jakarta), CIF, CFR, and DDP terms. Standard payment terms are 30% T/T deposit upon order confirmation and 70% balance against Bill of Lading (B/L) copy, or irrevocable L/C at sight for large institutional contracts.

Request Factory Direct Pricing & Free Sample Kit

Contact our sports flooring engineering team today for volume price tiers, custom mold feasibility, and free material swatch kits shipped to your door.

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Quanzhou Firefox New Material Co., Ltd.

Your Trusted Partner in High-Performance Athletic Flooring & Martial Arts Mats

Empowering sports brands, international dojos, fitness clubs, and tournament venues worldwide with precision polymer engineering and certified athlete protection.

Contact Our Engineering Team Visit Firefox Foam Official Website

As one of the most experienced sport mats suppliers in China, we have world-leading production equipment and strong manufacturing capabilities. Please rest assured to wholesale customized sport mats from our factory. For price consultation, contact us.