How Burnt Soul Created the Iconic Gladiators Outfits for the BBC Revival

I remember it so clearly - When the call came through from the producers at Hungry Bear - asking Burnt Soul to design a prototype outfit for the brand-new Gladiators revival on the BBC, I knew it was going to be a wild ride right from the get-go. From our tiny factory studio (in Bristol at the time) to the dazzling lights of the arena, we poured every drop of Wild Child energy into creating high-performance Lycra looks worthy of legends.

1. The Brief 

The brief for the BBC Gladiators costumes was surprisingly simple - and slightly terrifying. The producers wanted to see what we’d come up with without any creative direction. Just two rules:

1️⃣ The outfits had to be red or blue

2️⃣ They needed to be age-appropriate for a young audience

Knowing these would also need to survive serious combat, we steered clear of zips or fastenings that could break under pressure. Every outfit had to be climb-in only - which, for some of the larger Gladiators, was a workout in itself!

Lycra was the obvious (and only) choice - it’s what we do best. But I wanted to push it further, so we mixed the reds and blues in unexpected ways to give the designs more energy and individuality.

At Burnt Soul, we’ve always created pieces that make people feel confident, powerful, and unapologetically themselves - usually on dancefloors and festival fields. This time, it was about helping real-life warriors channel that same unstoppable energy on national TV.

Designing 16 iconic outfits under pressure? No big deal… right?

2. The Design Process

With a show as iconic as Gladiators, we wanted to nod to the 90s nostalgia of the original series — but give it a bold, futuristic twist. Think otherworldly warriors meets modern Lycra legends.

A few days after sending the first prototype to the producers, Robyn headed to London for the initial fitting with all sixteen soon-to-be Gladiators.

Her design process is always hands-on — quite literally working with the body as the canvas. With tight deadlines, the team created a simple base block (in true Burnt Soul style — pink leopard print, of course!) for each Gladiator. Robyn then used these as her templates, sketching and pinning style lines directly onto each person to tailor the designs perfectly to their unique shapes and strength.

What started as a pile of Lycra and marker pens quickly became the blueprint for some of the most powerful (and best-dressed) warriors on TV.

Sketching the future Gladiators!

3. The fittings

Back in the studio, it was all systems go. We worked non-stop to turn those pink leopard-print toiles into fully fledged Gladiator outfits.

Creating the patterns was no small feat. At Burnt Soul, everything is done by hand - no fancy CAD software or automated cutters here. Just Robyn, her patternmaster, and a lot of coffee. Each design was made up of 15 to 30 panels on average, meaning precision (and patience!) was key.

Once the patterns were ready, we got to work using fabrics from our long-time UK supplier, Friedmans - who absolutely deserve a shout-out here. We had to let them in on our little secret project, and they were incredible. They turned around bespoke foiled fabrics for us in just a few days and were total heroes in helping make the impossible happen.

Then it was back up to London for the final fitting before the big Hero Shoot. It was nerve-wracking but electric - every single Gladiator loved their outfit, and only minimal tweaks were needed.

(Oh, and if you look closely… you might just spot Giant’s elusive sleevelette that didn’t make the final cut 👀).

Tailoring every outfit to match each Gladiator’s power 

4. From Studio to Stadium

Now for the making - and this is where the BBC Gladiators outfits behind-the-scenes story really comes to life.

Each Gladiator needed between four and six identical outfits for filming, which meant a total of 76 costumes to cut, sew, and finish to perfection. Needless to say, the coffee machine worked overtime! 

The team absolutely pulled out all the stops - late nights, no weekends, and a whole lot of Lycra-fuelled determination. Every seam, foil panel, and power line was stitched right here in our Newquay studio before being packed up and sent off to Sheffield Arena for filming.

It was intense, exhausting, and completely unforgettable - the kind of project that reminds you why you fell in love with making clothes in the first place.

From the studio to Sheffield Arena

5. The Hero Shoot

Midway through production, Robyn and Hannah headed up to Manchester with 16 finished outfits in tow to film the graphics for the show. The Hero Shoot was nothing short of incredible to witness - the moment all those weeks of pattern-cutting, foiling, and fitting finally came to life under the studio lights.

To help the production team nail the lighting for the foil reflections, Hannah even stepped in as Athena for the morning - striking poses, testing movements, and helping capture that signature metallic glow on camera.

It was also our first time seeing the iconic pugil sticks in full swing (and yes, they’re just as dramatic in real life!). Watching all sixteen Gladiators together in their costumes for the first time was surreal - the energy, the colour, and the sense of power in the room was electric. You could feel the magic starting to build.

16 heroes, 16 custom-made Lycra suits – watching our designs come alive

6. The Arena 

As part of production, the team travelled up to Sheffield to see all our hard work come to life - foam hands at the ready, of course! Walking into that massive arena was a total goosebumps moment. The scale, the lights, the energy - it instantly transported me back to being a kid glued to the TV on Saturday nights.

The day was nothing short of epic. The crowd was electric, the kids were screaming for their favourite Gladiators, and the whole set was buzzing with energy. Watching those costumes in full action - stretching, shining, and standing up to the challenge - was one of those “we actually did it” moments.

You could tell right then that this reboot was going to be huge the moment it hit TV screens.

Feel the scale, the lights, the energy – Gladiators’ power in every stitch

7. The Burnt Soul Ethos in Action

For us, this project wasn’t just about making outfits for TV - it was proof that a female-led fashion studio from Cornwall can stand shoulder to shoulder with the biggest names in the industry. Every stitch and panel carried that signature Burnt Soul energy: bold, empowering, and unapologetically confident.

As an independent UK fashion brand, we’ve always championed creativity without compromise - designing, cutting, and sewing everything by hand in our own studio. The BBC Gladiators project was the ultimate showcase of what we do best: crafting performance wear that makes people feel powerful, fearless, and completely themselves.

These weren’t just costumes - they were confidence suits. And seeing them come alive under the arena lights was the moment it all clicked: the spirit of Burnt Soul was built for battle.

8. The Impact

We’re now three seasons in with no sign of slowing down - and it still feels surreal every time we see our foiled heroes lighting up the screen. The Gladiators adventure has grown even bigger, with a live UK tour now in full swing (and yes, we make those costumes too!).

Along the way, we’ve had the absolute pleasure of dressing a few honorary Gladiators - including Lenny Rush, Chris Ramsey, and Vernon Kay - for BBC Children in Need, which was such a proud moment for the team.

We can’t wait to see where this journey takes us next - one stitch, one sparkle, and one powerhouse outfit at a time.

Foiled, fearless, and full of confidence – Burnt Soul Gladiators making waves on screen

9. Becoming a Gladiator 

Whilst we’re not permitted to make official Gladiators outfits for the public, you can still channel your inner warrior with our customisable catsuits - available in a range of foils, including fierce reds and bold blues. Want cropped legs? No problem - just pop a note in at checkout, and we’ll make it happen.

💥 Want your own piece of power dressing?

Explore our Design Lab or head directly to our Customise your Kids' Catsuit for the mini hero in your life.

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Inspiring the next generation – mini heroes in bold, handmade Burnt Soul Lycra