Sublimation vs Screen Printing: The Technical Gear Guide
I’ve seen too many brand founders waste $500 on screen setups for a 50-piece order. It’s a rookie mistake that eats your profit before you even launch. Worse, I’ve seen pro teams play in screen-printed jerseys that feel like wearing a plastic bag in 40°C heat.
At our factory in Sialkot, we engineer both processes, but for high-performance jerseys, one is a legacy method and the other is the industrial standard. I’m Khan, and I’m going to show you the molecular science and manufacturing ROI behind your kit decoration. No kaam chori—just raw data.
👉 Sourcing a new team kit? Request a Technical Decoration Audit.
1. Technical Decoration Matrix: Bonding vs. Adhesion
Understanding the physics of how ink meets fabric is the first step to building a pro brand.
| Metric | Dye-Sublimation | Industrial Screen Print | The 'Performance' Factor |
|---|---|---|---|
| Bond Type | Molecular Fusion (Infused) | Surface Adhesion (PVC Film) | Sublimation never delaminates |
| Breathability | 100% Fabric Logic | Blocked (by Ink Film) | Essential for moisture cycling |
| Hand-Feel | Zero-Texture (Soft) | Slightly Raised / Ribbed | Sublimation is weightless |
| Durability | Lifetime of Fiber | 50-70 Wash Cycles | Sublimation won't crack |
| Setup Cost | Zero (Digital) | High ($25+ per Color) | ROI Logic for < 500 units |
2. Fabric Compatibility Matrix: Matching Method to Mesh
You cannot sublimate on everything, and you shouldn't screen print on everything.
| Fabric Material | Sublimation | Screen Printing | Technical Note |
|---|---|---|---|
| 100% Polyester | 5/5 Stars (Elite) | 3/5 Stars | Poly is built for dye-bonding |
| 100% Cotton | FAIL (No Bond) | 5/5 Stars | Cotton requires surface ink |
| CVC (60/40) | 2.5/5 Stars (Vintage) | 4/5 Stars | Sublimation looks "faded" on CVC |
| Nylon / Lycra | 4/5 Stars | 2/5 Stars | High stretch kills screen ink |
3. Cost Dilution Economics: The "Sponsor Tax"
If your jersey has 10 sponsors, screen printing will bankrupt you. Sublimation loves complexity.
| Order Volume | 1-Color Logo (Sub vs SP) | 10-Color Logo (Sub vs SP) | Why the Gap? |
|---|---|---|---|
| 50 Units | $12.50 vs $14.50 | $12.50 vs $35.00 | Screen setups are additive |
| 200 Units | $11.00 vs $11.50 | $11.00 vs $22.00 | Setup fees ruin small runs |
| 1,000 Units | $9.50 vs $8.50 | $9.50 vs $14.00 | SP wins only on simple mass |
4. Industrial Screen Printing Chem Matrix
Not all screen prints are the same. If you go this route, know your inks.
| Ink Type | The "Feel" | Breathability | Used For |
|---|---|---|---|
| Plastisol | Thick / Plastic | Zero | Standard Merch / Numbers |
| Water-Based | Soft / Minimal | Moderate | Premium Lifestyle Gear |
| Discharge | Bleaches Fabric | High | Vintage Cotton Hoodies |
| Silicon (3D) | High-Texture | Zero | Elite Team Crests |
5. Molecular Science: The Sublimation Transfer Profile
How does a solid ink become a permanent part of a jersey?
- The Print: High-viscosity Italian ink is printed onto a specialized transfer carrier.
- The Heat: The fabric and carrier are pressed at 200°C - 210°C for 35 seconds.
- The Gifting: Under heat, the polyester pores "open," and the solid ink turns into a gas.
- The Lock: As the fabric cools, the pores "close," locking the dye inside the polymer chain forever.
6. Competitive Landscape: Who are you buying from?
Don't let a "Local Print Shop" give you bad B2B advice.
| Service Provider | Specialty | Sourcing Capacity | MAVYQ Factory Benefit |
|---|---|---|---|
| POD (Redbubble) | 1-unit stickers | Generic Blanks | Direct Price / Pro Fabric |
| Local Screen Shop | Cotton Tees | Generic Blanks | Engineered Sublimation |
| Adidas/Nike Team | Templated Gear | Locked Designs | 100% Customization |
| MAVYQ Factory | High-Perf Kits | Floor-Direct | Maximum ROI / Design Freedom |
7. Troubleshooting: Common Decoration Failures
In Sialkot, some shops commit "Kaam Chori" (laziness). Here is what we prevent.
| Failure Mode | Root Cause | MAVYQ Solution |
|---|---|---|
| Dye Migration | Low-quality ink curing | 320°F Mandatory Tunnel Curing |
| Ghosting (Sub) | Improper pressure | Industrial Pneumatic Calenders |
| Logo Peeling | Improper ink-mix | Laboratory Grade Plastisol |
| Opacity (Sub) | Thin fabric (Grin-thru) | 160 GSM Min Weight Guarantee |
8. Landed Cost ROI for Brand Owners (Per Unit)
If you sell a jersey for $65, here is how your decoration choice affects your bank account.
| Order (100 Qty) | Manufacturing | Shipping (DHL) | Total Landed | Net Profit |
|---|---|---|---|---|
| Sublimated Kit | $13.50 | $4.50 | $18.00 | $47.00 |
| S/P Kit (5 Col) | $19.50 | $4.50 | $24.00 | $41.00 |
| Embroidered Kit | $22.00 | $5.00 | $27.00 | $38.00 |
9. Product Tier Spec Sheets: Decoration Logic
| Specification | Tier 1: Fan Merch | Tier 2: Pro-Match Kit | Tier 3: Elite Brand Drop |
|---|---|---|---|
| Decoration | Screen Print (1-2 Col) | Full Sublimation | Sublimation + 3D Silicon |
| Fabric | 140 GSM Mesh | 160 GSM Birdseye | 180 GSM Technical Jacquard |
| Lead Time | 14 Days | 21 Days | 30 Days |
| Unit Price | $8.50 - $11.50 | $12.50 - $14.50 | $18.50 - $22.50 |
10. Care Instructions for High-Performance Decorated Gear
To protect the $40+ margin in every garment:
- Machine Wash Cold (30°C max) to prevent ink softening.
- Wash Inside Out: Protects the surface adhesion (Screen Print) from friction.
- No Tumble Dry: High heat can reactivate sublimation gas or melt 3D silicon badges.
- No Fabric Softener: Softeners coat the "pores" of the polyester, killing the breathability you paid for.
Continue Your Technical Research
Related Products:
- Pro-Elite Sublimated Jerseys (MOQ 50)
- Heavyweight Screen-Printed Hoodies
- Custom Team Crest Services (3D Silicon/Embroidery)
Related Technical Guides:
- How to Design an Esports Jersey for Maximum ROI
- Esports Jersey Pricing 2026: The Manufacturing Guide
- Wholesale Hoodies Buying Guide 2026: Technical Overview
- MOQ Explained: The Manufacturing Reality
Start Your Order:
MAVYQ — Technical Decoration & Manufacturing | Sialkot-Direct | ISO 9001 Certified
