Blog

Choosing the right printing method for your team jerseys can make or break the final result. The technique you choose affects color vibrancy, durability, comfort, cost, and how much freedom you have in your design. Two of the most popular options for custom team jerseys are sublimation and screen printing—but they work very differently and are not interchangeable.

This guide breaks down how each method works, their pros and cons, costs, and when to choose each one, so you can make the best decision for your team or brand.

What Is Sublimation Printing?

Sublimation is a process where special inks turn into gas under heat and pressure, then bond permanently with polyester fibers. The design becomes part of the fabric instead of sitting on top of it.

How Sublimation Works

• A design is printed on transfer paper using sublimation ink.
• The printed paper is placed on a polyester garment.
• Under high heat and pressure, the ink turns into gas and fuses with the fibers.
• The result is a permanent, full-color design that is embedded in the fabric.

Because the ink is inside the fibers, you cannot feel the print on the surface of the jersey.

Key Advantages of Sublimation

• Unlimited colors at no extra cost – Gradients, patterns, photos, and full-color artwork are all possible without per-color fees.
• No cracking, peeling, or fading – The design becomes part of the fabric, so it lasts as long as the jersey itself.
• Lightweight and breathable – There is no added ink layer, so the fabric retains its original stretch and airflow.
• All-over print coverage – You can print on the entire jersey (front, back, sleeves, side panels, collar).
• Perfect for complex designs – Ideal for modern, dynamic, or highly branded team looks.

Limitations of Sublimation

• Requires polyester – Sublimation only works properly on polyester or high-polyester blends, usually light or white fabrics.
• Not ideal for dark cotton garments – You cannot sublimate vivid, solid designs onto dark cotton shirts.
• Upfront setup – Each fully custom template requires pattern, layout, and design setup.
• Specialized production – Not every print shop offers true sports-grade sublimation.

What Is Screen Printing?

Screen printing is a traditional technique where ink is pushed through a mesh stencil (screen) onto the fabric. Each color in the design requires its own screen.

How Screen Printing Works

• A separate screen is created for each color in the design.
• Ink is pulled across the screen and transferred onto the jersey.
• Layers are built up color by color.
• The ink is cured under heat so it bonds to the surface of the fabric.

The result is a layer of ink that sits on top of the fabric and can be felt when you touch the print.

Key Advantages of Screen Printing

• Bold, solid colors – Great opacity and vibrancy, especially on dark garments.
• Works on many fabrics – Suitable for cotton, cotton blends, and polyester.
• Cost-effective for large quantities – Once screens are made, big runs reduce the per-piece cost.
• Simple logos and numbers look great – Perfect for straightforward team designs with few colors.

Limitations of Screen Printing

• Per-color cost – Each color needs its own screen, so complex designs can become expensive.
• Limited detail for full-color artwork – Photorealistic images and complex gradients are harder and costlier.
• Heavier feel – Large printed areas can feel thick and less breathable.
• Cracking and fading over time – With repeated washing and heavy use, the ink layer can eventually crack or fade.
• Not ideal for all-over designs – Usually limited to specific print areas (front, back, sleeve).

Side-by-Side Comparison: Sublimation vs Screen Printing

Feature	Sublimation	Screen Printing
Best Fabric	100% polyester (light/white)	Cotton, blends, polyester
Print Feel	No feel – part of the fabric	Raised ink layer – can be felt
Color Range	Unlimited colors, gradients, full-color artwork	Limited by screens – best for solid colors
Design Complexity	Ideal for complex, detailed, all-over designs	Best for simple logos and text
Durability	Excellent – no cracking or peeling	Good, but can crack or fade over time
Breathability	Excellent – fabric breathes normally	Can reduce breathability on large print areas
All-Over Print	Yes, full garment possible	No, mostly localised areas
Cost Structure	Flat per piece; setup more about pattern/template	Cheaper at high volume, but cost per color adds up
Minimum Order Consideration	Efficient even at modest quantities	Best value at medium to large quantities
Best Use Case	Performance team jerseys & complex branded kits	Basic team tees, simple logos, practice wear

When Sublimation Is the Better Choice

Sublimation is usually the best option when:

• You want professional-level performance jerseys
  For football, basketball, soccer, baseball, running, or multi-sport kits where players need lightweight, breathable, moisture-wicking fabrics.
• Your design is complex or full-color
  Gradients, fades, patterns, flags, photographic elements, or multiple sponsor logos.
• You need all-over coverage
  Designs that wrap around the jersey, side panels, sleeves, and shoulders.
• You want long-term durability
  Jerseys that will last multiple seasons without cracking or peeling.
• You are using polyester performance fabrics
  Moisture-wicking, quick-dry fabrics for serious athletes.

For premium team jerseys that look and feel like professional kits, sublimation is almost always the superior option.

When Screen Printing Is the Better Choice

Screen printing is usually the best option when:

• You have a simple design with few colors
  Basic logo on the chest, text, and maybe a number for school teams, casual leagues, fan shirts, and promotional tees.
• You need cotton or lifestyle garments
  Hoodies, sweatshirts, cotton t-shirts, or casual apparel for supporters, staff, or off-field wear.
• You are ordering large quantities
  Event shirts, fan gear, or big club orders where per-piece cost needs to be very low.
• You don’t need all-over coverage
  Standard front/back prints are enough for your needs.
• You’re working with a tight budget for simple jerseys
  Screen printing on basic tees can be more economical than fully sublimated kits.

For training shirts, fan gear, and simple team tops, screen printing is still a strong, cost-effective option.

Cost Considerations: Which Is Cheaper?

Cost depends on your design, quantity, and garment type—not just the technique.

Costs for Sublimation

• Usually priced per jersey, not per color.
• Complex, full-color designs do not raise print cost.
• Best value when you want premium, pro-style uniforms.
• Ideal for teams that care about long-term durability and appearance.

Costs for Screen Printing

• Setup fees for each color (screens).
• Per-piece cost drops significantly at higher quantities.
• Simple 1–2 color logos are very affordable.
• Costs increase quickly with more colors and print locations.

Rule of Thumb:

• Simple design + large quantity + cotton → Screen printing is often cheaper.
• Complex design + performance fabric + pro look → Sublimation offers better value.

Performance: Comfort, Breathability, and Durability

Comfort & Breathability

• Sublimation: Since the ink becomes part of the fabric, the jersey remains as soft, flexible, and breathable as the base fabric. This is ideal for competitive athletes who need maximum comfort.
• Screen Printing: On small logo areas, the difference is minimal. But large solid prints can feel heavier and less breathable, especially in hot conditions.

Durability & Longevity

• Sublimation: The design cannot crack or peel because there is no physical ink layer on top. If the fabric is intact, the design is intact.
• Screen Printing: High-quality inks and curing processes last a long time, but over many washes and heavy use, prints can crack, fade, or peel—especially on heavily used jerseys.

Design Flexibility and Branding

If branding and style are important for your team or sportswear brand, sublimation opens far more creative possibilities.

What You Can Do with Sublimation

• Full-jersey gradients and patterns.
• Integrated flags, textures, or camo designs.
• Multiple sponsor logos without extra color cost.
• Detailed number styles and name fonts.
• Unique designs per player (for example, custom names and numbers on every jersey).

What You Can Do with Screen Printing

• Bold logo on chest or back.
• Simple text and numbers.
• Single or dual-color branding.
• Classic, minimal look.

If you want your team to stand out visually—especially on social media, in photos, or in competitive leagues—sublimation gives you far more room to be creative.

Which Is Best for Your Team Jerseys?

Use this quick decision guide:

Choose Sublimation If:

• You want professional-level team jerseys.
• You’re using polyester sports fabrics.
• Your design is complex, colorful, or all-over.
• You want maximum breathability and comfort.
• You care about long-term durability and no cracking or peeling.

Choose Screen Printing If:

• You’re printing on cotton or hoodies.
• Your design is simple and uses only 1–3 colors.
• You’re ordering large quantities at the lowest possible cost.
• You’re making training tees, fan gear, or casual tops.

How Runnics Sports Can Help

With both sublimation and high-quality printing available for custom team jerseys, you can choose the method that truly fits your team, budget, and design.

You can:

• Order fully custom sublimated jerseys on performance polyester.
• Use screen-printed training tees, hoodies, and casual apparel alongside your game kits.
• Get expert guidance on the best method for your sport, design, and budget.
• Take advantage of low minimums so even small teams and startup brands can get professional results.

Ready to Choose the Right Method?

If you already have a design, you can decide based on these two questions:

1. Is your jersey fabric polyester performance material and your design complex or all-over?
   If yes, choose sublimation.
2. Is your jersey cotton or a simple logo-only design, especially in large quantities?
   If yes, choose screen printing.

If you’re not sure, the safest option is to request samples of both methods on the actual fabric you plan to use, then compare how they look, feel, and perform.

 

Ready to create custom jerseys that look and feel professional?

• Finalize your design (or get help refining it).
• Decide where you’ll use the jerseys (game, training, or casual).
• Choose sublimation or screen printing based on this guide.
• Place your order and let your team step onto the field in jerseys they’re proud to wear.

Whether you’re building a serious sports program or a growing apparel brand, choosing the right print method is a key part of getting jerseys that perform as well as your players.