How to Cut Fuji Tatami or MMA Mats for a Perfect Fit: A Step-by-Step Guide

Are you setting up some Tatami or MMA Mats at home, in your gym, dojo, or commercial fitness space and need your Fuji Tatami or MMA mats to fit perfectly? Whether you're dealing with irregular room shapes or obstacles like poles and pillars, cutting your mats is a straightforward DIY task that ensures safety, aesthetics, and functionality. Fuji Mats Australia offers premium, durable tatami and MMA mats designed for easy customisation, but proper cutting techniques are key to avoiding waste and achieving a professional look.

In this comprehensive guide, we'll walk you through how to cut Fuji mats for a seamless fit, including straight cuts for room sizing and specialised obstacle cutting around poles or pillars. As Australia's leading supplier of high-quality martial arts and gym flooring, we know the ins and outs of these products—follow our tips to get it right the first time.

Why Custom Cut Your Fuji Tatami or MMA Mats?

Custom cutting your Fuji mats isn't just about fitting them into your space; it's about maximising safety and performance. Ill-fitting mats can create both trip and trapping hazards and can compromise shock absorption during training. Fuji Tatami mats, with their traditional Japanese-style texture, and Fuji MMA mats, featuring a smooth vinyl surface for grappling, are both made from high-density EVA foam that's resilient yet easy to cut.

Whether you're outfitting a BJJ academy in Melbourne, a karate dojo in Sydney, or a home workout area in Brisbane, precise cuts ensure your investment lasts. Plus, with Fuji Mats Australia's nationwide delivery, you can order exactly what you need and trim the excess yourself—saving time and installation $$$.

Tools and Materials You'll Need

Before diving in, gather these essentials for safe and accurate cuts:

	Sharp Utility Knife or Box Cutter: Use a heavy-duty 25mm blade for clean slices through the foam.
	Straight Edge or Metal Ruler: At least 1-2 metres long for guiding straight cuts.
	Measuring Tape: Accurate measurements are crucial—measure twice, cut once!
	Marker or Chalk: For marking cut lines on the matss Use a thin 1mm whiteboard marker for easy wipe off.
	Cutting Mat or Protective Surface: To avoid damaging your floor.
	Safety Gear: Gloves, knee pads, and eye protection to prevent injuries. Prevention is the best medicine.
	Optional: Jigsaw or Circular Saw: For thicker mats or curved cuts around obstacles (use a fine-tooth blade to minimise tearing). Buy your Fuji Mat Cutting Blades here

Fuji mats are typically 40mm thick, so ensure your tools can handle the depth. If you're unsure, contact Fuji Mats Australia for advice on compatible tools.

Step-by-Step: Cutting Fuji Mats to Fit Your Space

For basic resizing—such as trimming mats to match your room dimensions—focus on straight, precise cuts. This method works for both Fuji Tatami and MMA mats.

Measure Your Space Accurately Start by measuring the area where the mats will go. Account for any expansion gaps (about 5-10mm around walls) to allow for foam expansion in Australia's varying climates. Lay out your mats in a dry run to visualise the fit.
Mark the Cut Lines Mark the cut line on the top of the surface. Ensure you add 1mm and cut on the inside of your line so that you cut away the line you just marked. Alternatively, flip the mat upside down (foam side up) to avoid marking the visible surface. Use your measuring tape and straight edge to draw clear lines with a marker. For tatami mats, align cuts with the grain if possible for a cleaner edge.
Make the Initial Score Hold the straight edge firmly along the line and score the mat with your utility knife, applying even pressure. Go about halfway through the thickness on the first pass—don't force it all at once to prevent jagged edges.
Complete the Cut Fold the mat along the score line and cut through the remaining foam from the back. For thicker sections, make multiple passes. Smooth any rough edges with sandpaper or a file for a professional finish.
Test the Fit Place the cut mat in position and check for gaps. If needed, trim incrementally—it's easier to remove more than to add back!

This process ensures your Fuji mats hug the floor perfectly, reducing movement during intense sessions like Jiu-Jitsu or wrestling.

Advanced Techniques: Cutting Around Obstacles Like Poles and Pillars

Obstacles such as support poles, pillars, or fixed gym equipment such as require curved or notched cuts for a snug fit. Here's how to handle them without compromising the mat's integrity.

Assess the Obstacle Measure the diameter or shape of the pole/pillar. Add a 5mm buffer for easy installation and to prevent buckling.
Create a Template Use cardboard or paper to trace the obstacle's outline. Place it on the mat's underside and trace around it with chalk. This template ensures accuracy for irregular shapes.
Score the Outline For circular cuts (common around poles), use a utility knife to score along the traced line. If the obstacle is square or rectangular, combine straight cuts with corner notches.
Cut Through Carefully For curves, a jigsaw with a foam-cutting blade works best—set it to low speed to avoid melting the EVA. Start from the edge and follow the score, or cut in sections for pillars. Pull away excess foam as you go.
Refine and Install Test-fit the mat around the obstacle. Trim any tight spots and use adhesive tape or Fuji mat connectors if needed for stability. For MMA mats, ensure the vinyl top remains intact to maintain grip.

Pro Tip: Always allow mats to acclimate for 24 hours before cutting to account for slight expansion. Especially in hot and humid Australian environments, like Queensland,

Safety Tips and Common Mistakes to Avoid

Prioritise Safety: Always cut away from your body and on a stable surface. Fuji mats are non-toxic, but wear a mask if dust is an issue.
Avoid Over-Cutting: Start conservative—you can always trim more.
Mat-Specific Advice: Tatami mats' textured surface hides minor imperfections better than smooth MMA mats, so practice on scraps.
When to Seek Professional Help: For large-scale installations or complex obstacles, consider Fuji Mats Australia's installation services across Australia.

Common pitfalls include using dull blades (leading to tears) or ignoring measurements, which can waste expensive mats. Remember, Fuji Mats are built to last 10+ years with proper care.

Achieve the Perfect Fit with Fuji Mats

Cutting your Fuji Tatami or MMA mats for a custom fit is an empowering way to tailor your training space exactly to your needs. Whether it's simple resizing or navigating around poles and pillars, these steps ensure a safe, professional result that enhances your workouts.

Ready to get started? Browse our range of F uji Tatami Mat s and MMA Mats at Fuji Mats Australia—Australia's trusted source for premium martial arts flooring. With fast shipping to all states and expert advice, we're here to help. Contact us today for a quote or more tips!

For more helpful hints and tips, watch the Video Below for more helpful hints on how to measure and cut Tatami or MMA Mats...

How to Cut Tatami or MMA Mats for your Gym