Sublimation vs. Screen Printing: The Ultimate Guide to Choosing Your Next Team Jerseys

As experts who live and breathe custom sports apparel every day, we're here to demystify the process. This guide will walk you through everything you need to know, helping you make a confident choice that fits your team's budget, design vision, and performance needs.

What is Screen Printing? A Time-Tested Classic

Screen printing (also known as serigraphy) is the traditional, tried-and-true method for printing graphics onto fabric. If you have a classic cotton t-shirt with a bold, simple logo, it was likely screen printed. The process is a form of stenciling where ink is pushed through a mesh screen onto the garment.

1. Design Separation: First, your design is broken down into its individual colors. Each color requires its own separate screen. A three-color logo (say, blue, white, and yellow) will need three different screens.
2. Screen Creation: A fine mesh screen is coated with a light-sensitive emulsion. Your design for a single color is printed onto a transparent film, which is then placed on the screen and exposed to bright light. The light hardens the emulsion everywhere except where the design is. The unhardened emulsion is then washed away, leaving a perfect stencil of that color's design on the screen.
3. Ink Application: The jersey is laid flat on a printing press. The screen for the first color is placed on top of it. A thick, opaque ink is poured onto the screen, and a squeegee is used to press the ink firmly through the mesh stencil and onto the fabric.
4. Layering Colors: The process is repeated for each color, with a flash-curing heat treatment between each layer to dry the ink. Precision is key to ensure all the colors line up perfectly (a process called registration).
5. Final Curing: Once all colors are applied, the entire jersey passes through a large conveyor dryer. This high heat cures the ink, forming a strong, durable bond with the fabric. The result is a graphic that sits on top of the fabric, creating a distinct, slightly raised texture.

When is Screen Printing the Right Call?

 

The Pros of Screen Printing:

• Vibrant, Opaque Colors: Screen printing ink is thick and sits on the fabric's surface. This makes it incredibly vibrant and opaque, especially on dark-colored garments. A bright white logo will look crisp and bright on a black jersey.
• Cost-Effective for Large Orders: The main cost is in the setup (creating the screens). Once the screens are made, printing additional jerseys is fast and cheap. This makes it highly economical for large batches (typically 12 items or more) with the same design.
• Durable for Simple Designs: For logos with one or two colors, a properly cured screen print is tough and can withstand many washes.
• Works on Many Fabrics: While ideal for cotton and cotton blends, screen printing is versatile and can be used on polyester, though the feel might be less ideal for performance wear.

The Cons of Screen Printing:

• Limited Design Complexity: Because each color requires a separate screen and setup, complex designs with many colors, gradients, or photographic elements become prohibitively expensive and difficult to execute.
• Not Ideal for Small Orders: The high setup cost for the screens makes it uneconomical for small batches or for orders where every jersey needs a different name or number.
• The Feel of the Print: The ink layer sits on top of the fabric. On a performance jersey, this can create a heavier, non-breathable patch right where the design is, which can be noticeable to athletes.
• Potential for Cracking/Fading: Over time and many washes, the raised ink layer can crack, peel, or fade, especially if not cared for properly.

Choose Screen Printing If:

• You have a simple, bold logo with 1-3 solid colors.
• You are ordering a large quantity (12+) of the same design.
• You are printing on cotton or cotton-blend shirts for fans or sideline apparel.
• Cost-effectiveness on a large batch is your primary concern.

What is Dye-Sublimation? The Modern Performance Standard

Dye-sublimation is a modern, digital printing technology that has revolutionized the world of performance sportswear. Instead of placing ink on top of the fabric, sublimation infuses dye directly into the fibers of the garment.

Digital Printing: Your entire design—logos, colors, gradients, names, numbers, and even complex backgrounds—is printed as a single, complete image onto a sheet of specialized transfer paper using sublimation-specific inks.

Heat Press Preparation: A blank, typically white, polyester garment is laid flat on a large industrial heat press. The printed transfer paper is placed face-down on top of the jersey.

The "Sublimation" Process: The heat press closes, applying intense pressure and high heat (typically around 200°C / 400°F). The magic happens here: the heat causes the solid inks on the paper to turn directly into a gas (this is "sublimation"), bypassing the liquid state.

Dye Infusion: The gaseous dye is forced into the polyester fibers, which open up from the heat. As the press cools, the fibers trap the dye, permanently infusing the design into the fabric itself.

Final Product: The transfer paper is peeled away, revealing a jersey with a flawless, full-color design. There is no texture, no raised ink—the design is now a part of the fabric.

 

When is Dye-Sublimation the Right Call?

 

The Pros of Dye-Sublimation:

Unlimited Design Freedom: The biggest advantage. You can print anything: photographic images, intricate patterns, gradients, and an unlimited number of colors, all for the same price. Want a jersey that looks like a galaxy? Or a cityscape? Sublimation can do it.

Zero Feel and 100% Breathable: Because the dye is infused into the fibers, you cannot feel the print at all. The jersey remains perfectly soft, lightweight, and breathable across its entire surface, which is ideal for athletic performance.

Supreme Durability: A sublimated design will never crack, peel, or fade. It is as durable as the fabric itself and will last the entire life of the garment.

Perfect for Customization: Adding individual player names and numbers is incredibly easy and adds no extra cost, as each print is a unique digital file.

The Cons of Dye-Sublimation:Only Works on Polyester: The sublimation process requires synthetic fibers that can open up to accept the dye. It does not work on natural fabrics like 100% cotton. (Works on poly-blends, but colors will be less vibrant). For performance sportswear, this is rarely an issue as most jerseys are 100% polyester.

Starts with White Fabric: Sublimation is a dyeing process, not an opaque ink application. Therefore, it must be done on white or very light-colored fabric for the colors to be true. You cannot sublimate a light color onto a dark jersey.

Higher Per-Item Cost on Simple Jobs: For a very large order of simple, one-color logos, the per-item cost of sublimation might be slightly higher than screen printing due to the labor and materials involved in printing and pressing each jersey individually.

 

Choose Dye-Sublimation If:

Your design is complex, has many colors, gradients, or photographic elements.

You need individual names and numbers on each jersey.

Performance, breathability, and a lightweight feel are top priorities.

You want maximum durability with zero chance of the design cracking or fading.

You are ordering for performance sports like soccer, basketball, volleyball, or hockey.

Head-to-Head Comparison: Sublimation vs. Screen Printing

 

 

The Verdict: Which Process Should Your Team Choose?

 

Let’s make it simple. Look at your design and think about your team’s primary needs.

You are a perfect candidate for Screen Printing if...

You’re a school club, a corporate event, or a team needing sideline fan wear. Your logo is simple (think a classic crest with one or two colors), you’re ordering in bulk to keep costs down, and the shirts are primarily cotton or cotton blends.

You are a perfect candidate for Dye-Sublimation if...

You are a sports team of any kind—soccer, basketball, volleyball, esports, you name it. Your design involves multiple colors, a detailed background pattern, gradients, or requires individual player names and numbers. You demand high performance, meaning the jersey must be lightweight, fully breathable, and incredibly durable. You want your uniform to look just as vibrant in the championship game as it did on day one.

For 9 out of 10 sports teams we work with, dye-sublimation is the winning choice. It offers unparalleled design freedom and superior athletic performance that screen printing simply cannot match.

Ready to Create Your Perfect Jersey?

Navigating these choices is our specialty. Whether you have a complete design ready to go or just a rough idea sketched on a napkin, our team is here to guide you to the perfect solution. We can show you samples, help you optimize your design for either process, and ensure your team steps onto the field or court looking and feeling their absolute best.

Contact us today for a free, no-obligation quote. Let's build a jersey that your team will be proud to wear.