Sublimation vs Screen Printing Jerseys: Which Suits Your Kit?

By the Oversky International team

In the sublimation vs screen printing jerseys debate, the fabric usually decides. Sublimation turns dye into a gas that bonds with polyester fibres, so full-colour, all-over designs cost the same as simple ones and will not crack or peel. Screen printing lays ink on the surface, suits cotton and blends, and needs a separate screen for every colour.

How does sublimation printing work?

Sublimation prints the design onto transfer paper, then uses heat and pressure to turn the dye into a gas that bonds with the polyester in the fabric. The colour becomes part of the fibre rather than a layer on top of it.

Because the dye bonds with polymer fibres, the method depends on fabric content. Printer makers such as Epson note that higher polyester content gives more vibrant results, and many makers treat roughly 60-65% polyester as a working minimum (Denver Public Library makerspace guide). On 100% cotton the dye has nothing to bond with, so the print washes out.

For teamwear, that suits the fabrics most kits already use: polyester mesh, interlock and performance knits. The print covers the whole panel, including side seams and sleeves, because the fabric is printed before the garment is cut and sewn.

How does screen printing work?

Screen printing pushes ink through a fine mesh stencil onto the garment, one colour at a time. Each colour in the artwork needs its own screen, so a three-colour logo needs three separate screens, aligned so the colours sit in register.

The ink sits on top of the fabric and is heat-cured to bond. That makes screen printing a strong choice for cotton and cotton-rich blends, for bold spot colours, and for one or two-colour logos on training tees, hoodies and supporter wear. Each extra colour adds a screen to make, expose and line up, so cost rises with colour count.

Sublimation vs screen printing: side-by-side comparison

The table below compares the two methods on the points buyers usually weigh when they brief a kit.

Which method is better for team jerseys?

For most modern match jerseys, sublimation is the better fit. Kits are usually polyester, designs often run edge to edge, and players want a light shirt that breathes and keeps its colour wash after wash.

Sublimation also handles names, numbers and sponsor logos in the same pass as the main design, which keeps production simple. Screen printing earns its place when the garment is cotton, when the design is one or two flat colours, or when you want a raised, opaque print on a dark garment. Sublimation dye is transparent, so it cannot print light colours onto a dark base fabric; the design has to build the dark colour in rather than print over it.

Many clubs mix both: a sublimated match kit from our teamwear range, with screen-printed cotton tees and hoodies for fans and travel.

Does sublimation crack or fade?

Sublimation does not crack or peel, because there is no ink layer to break. Colour fastness depends on the dye, the fabric and how the garment is washed, so follow the care label and avoid very hot washes and tumble drying where the label says so.

Screen prints can crack over time if the ink is under-cured or the garment is stretched hard. Good curing and the right ink for the fabric reduce that risk. On stretchy performance fabrics, a stretch additive in the ink helps the print move with the garment.

How do you choose the right method for your order?

Start with the garment and fabric, then look at the artwork. Answer these in order and the method usually chooses itself:

1. What is the fabric? Polyester points to sublimation; cotton points to screen printing or transfers.
2. What colour is the base? Light or white bases suit sublimation; dark bases with light prints suit screen printing.
3. How many colours are in the design? Gradients, photos or many colours favour sublimation.
4. Does the print cover the whole garment? All-over designs need sublimation.
5. How should it feel? If players want no added layer, choose sublimation.

If you are unsure, send the artwork with your brief and we will recommend a method for each garment. You can also sketch layouts and colourways in our Team Kit Designer before you ask for a quote.

Frequently asked questions

Can you sublimate on cotton?

Not well. Sublimation dye bonds with polyester, so on 100% cotton most of the colour washes out. Cotton-rich blends give a faded, vintage look. For cotton tees and hoodies, choose screen printing or a transfer instead, or switch the garment to a polyester performance fabric.

Is sublimation more expensive than screen printing?

It depends on the design. Sublimation has no per-colour set-up, so complex, multi-colour or all-over designs are often better value. Screen printing can be economical for one or two-colour logos on cotton, though each additional colour adds a screen. Send your artwork and quantities for a like-for-like quote.

Can names and numbers be sublimated?

Yes. On a sublimated kit, player names and numbers are usually printed in the same process as the rest of the design, so there is no extra layer to peel. Send a roster with each player's name, number and size, and check your competition's number rules before artwork is finalised.

What is the minimum order for printed teamwear?

At Oversky most designs start at 50 pieces per style and colour, whichever print method you choose. Smaller trial runs can be quoted for repeat customers or simple constructions. Our minimum order quantity guide explains how the count works.

What to do next

Send your artwork, fabric preference and quantities through the quote form on our homepage. We reply within one business day and will recommend sublimation, screen printing or a mix for each garment in your kit.