Thickness sets feel, durability and the handle diameter a player ends up with. A 0.5 mm overgrip barely changes the handle; a 1.8 mm replacement grip can add a full size. Brands that sell the same graphic across two thicknesses usually find the thicker version returns fewer complaints, because it hides handle irregularities and lasts longer under sweat.
Width and length by sport
Tennis overgrips run 25 to 27 mm wide and 1.0 to 1.2 m long; badminton grips are narrower at about 25 mm with a similar length; hockey cloth tape is 24 or 25 mm wide in 18 to 25 m rolls. Squash and padel follow tennis, though padel handles are shorter and use less tape per wrap.
- State width in millimetres with a tolerance of plus or minus 1 mm
- State thickness with a tolerance of plus or minus 0.05 mm
- Give roll length and a minimum usable length, not just nominal
- Specify core inner diameter, usually 25 mm or 38 mm
Tolerances that decide whether a roll runs
Automatic wrapping machines are less forgiving than hand application. A roll that is 0.03 mm over thickness can jam a slitting line, and a core that is 1 mm oversize will not seat on the mandrel. Put the measurable values on the purchase order: backing thickness, adhesive coat weight, peel adhesion in N per 25 mm, elongation at break, and roll winding tension.
Building a colour and SKU range
Retail ranges usually need six to eight colours plus black and white, and each colour is a separate minimum run. Keeping one backing and one adhesive across the range reduces changeover cost, while changing only the pigment. Ask for a master carton plan that mixes colours, so smaller brands can reach a workable order quantity without holding slow-moving stock.
