In 1990, Carlos Machado made the pivotal decision to move to the United States, initially to help the Gracie family establish their presence in the American market. As the Machado brothers found their footing in a new country, they eventually parted from the Gracie Jiu-Jitsu banner to operate independently under their own identity.
Carlos, alongside brothers Rigan and Roger, established himself in Redondo Beach, California, offering private lessons and steadily cultivating a dedicated student base — a distinct operation from the Tarzana location run by Jean Jacques and John Machado. It was during this Redondo Beach period that Chuck Norris, already a martial arts legend in Hollywood, became one of their most prominent early students, a relationship that would prove instrumental to Carlos's future.
In 1995, Carlos relocated to Texas, with Chuck Norris playing a central role in facilitating his transition. Carlos began teaching from the studio where Walker, Texas Ranger was filmed, introducing serious BJJ instruction to a new region of the country before expanding into his own dedicated facility as demand grew. His connection to the production extended on screen as well, with Carlos appearing in dozens of episodes during his time in Texas — a level of mainstream visibility that few BJJ practitioners of the era could claim.