Master Guide to Apparel Printing & Customization Methods
Compare 10+ printing techniques to choose the perfect method for your custom sportswear project.
Get Method RecommendationQuick Printing Method Comparison Table
| Method | Best For | Colors | Feel | Durability | Min Order | Cost | Rating |
|---|---|---|---|---|---|---|---|
| Sublimation | Jerseys, full designs | Unlimited | No feel | Lifetime | 50 | $ | ⭐⭐⭐⭐⭐ |
| Screen Printing | Simple logos, text | 1-6 | Slight raise | 50+ washes | 50 | $$ | ⭐⭐⭐⭐ |
| DTG Printing | Photos, complex art | Unlimited | Soft | 40 washes | 1 | $$$ | ⭐⭐⭐⭐ |
| Embroidery | Logos, premium look | 15 max | Raised texture | Lifetime | 25 | $$$ | ⭐⭐⭐⭐⭐ |
| Heat Transfer | Names, numbers | Solid colors | Smooth vinyl | 30 washes | 1 | $$ | ⭐⭐⭐ |
| Tackle Twill | Sports numbers | Solid colors | Layered fabric | Lifetime | 25 | $$$$ | ⭐⭐⭐⭐⭐ |
Detailed Printing Method Breakdowns
Sublimation Printing
The Gold Standard for Sports Jerseys
Heat and pressure turn solid dye into gas that bonds with polyester fibers. The design becomes part of the fabric itself.
Process:
- 1.Design printed on special transfer paper
- 2.Paper placed on polyester fabric
- 3.Heat press at 400°F for 60 seconds
- 4.Dye converts to gas and bonds with fibers
- 5.Design is permanent and breathable
Pros:
- • Unlimited colors and gradients
- • No additional texture or weight
- • Never cracks, peels, or fades
- • Full garment coverage possible
- • Most cost-effective for complex designs
Cons:
- • Only works on polyester
- • Can't print on dark fabrics
- • Slight color variation possible
- • Not suitable for cotton
Ideal For:
- • Sports jerseys
- • Athletic wear
- • All-over prints
- • Photo-realistic designs
- • Team uniforms with gradients
Not Recommended For:
- • Cotton garments
- • Dark base colors
- • Small text under 6pt
- • Metallic effects
Cost Breakdown:
Screen Printing
The Traditional Workhorse
Ink is pushed through mesh screens with stencils, one color at a time. Most common method for t-shirts worldwide.
Process:
- 1.Create separate screen for each color
- 2.Apply emulsion and burn design
- 3.Place screen on garment
- 4.Squeegee pushes ink through mesh
- 5.Cure with heat for permanence
Pros:
- • Vibrant, opaque colors
- • Works on all fabric types
- • Very durable prints
- • Cost-effective for large runs
- • Special inks available (metallic, glow)
Cons:
- • Limited colors (setup per color)
- • Not good for photographs
- • Can feel heavy with many colors
- • Minimum quantities required
Ideal For:
- • Bold, simple designs
- • Text and logos
- • Large quantity orders
- • Single color prints
- • Cotton t-shirts
Not Recommended For:
- • Photographic images
- • Small quantities
- • Gradient designs
- • Super detailed artwork
Cost Breakdown:
Direct-to-Garment (DTG)
Digital Printing Revolution
Like an inkjet printer for clothes. Water-based ink is sprayed directly onto fabric and absorbed by fibers.
Process:
- 1.Garment pretreated with solution
- 2.Loaded onto printer platen
- 3.CMYK inks printed directly
- 4.Heat cured for washability
- 5.No screens or transfers needed
Pros:
- • Unlimited colors included
- • Perfect for photographs
- • No minimum quantities
- • Soft hand feel
- • Quick turnaround
Cons:
- • Works best on cotton
- • Not as vibrant on dark colors
- • More expensive per piece
- • Can fade over time
Ideal For:
- • Small batch orders
- • Photographic designs
- • Artistic prints
- • One-off samples
- • Complex multi-color designs
Not Recommended For:
- • Polyester jerseys
- • Neon colors
- • Large solid areas
- • Rush bulk orders
Cost Breakdown:
Embroidery
The Premium Professional Choice
Threads are stitched directly into fabric creating a raised, textured design. Most durable and professional method.
Process:
- 1.Design digitized into stitch file
- 2.Fabric hooped and stabilized
- 3.Machine stitches design
- 4.Up to 15 colors per design
- 5.Backing trimmed and cleaned
Pros:
- • Premium, professional appearance
- • Extremely durable
- • 3D texture adds value
- • Works on any fabric
- • Perceived higher quality
Cons:
- • More expensive
- • Limited to simpler designs
- • Maximum practical size limits
- • Can pucker thin fabrics
Ideal For:
- • Corporate logos
- • Caps and hats
- • Polo shirts
- • Small chest designs
- • Premium team apparel
Not Recommended For:
- • Large designs
- • Photographic images
- • Gradient effects
- • Super thin fabrics
Cost Breakdown:
Heat Transfer Vinyl (HTV)
Perfect for Names & Numbers
Pre-colored vinyl is cut into shapes and heat-pressed onto garments. Popular for personalizing sportswear.
Process:
- 1.Design cut from colored vinyl
- 2.Excess vinyl weeded away
- 3.Transfer tape applied
- 4.Heat pressed onto garment
- 5.Carrier peeled away
Pros:
- • Great for names/numbers
- • No minimum quantities
- • Crisp, clean edges
- • Stretchy options available
- • Quick production
Cons:
- • Limited to solid colors
- • Can peel if not applied properly
- • Feels like plastic layer
- • Not breathable
Ideal For:
- • Player names
- • Jersey numbers
- • Simple text
- • Single color logos
- • Last-minute additions
Not Recommended For:
- • Complex designs
- • Gradient effects
- • Large coverage areas
- • Detailed artwork
Cost Breakdown:
Tackle Twill
Pro-Level Athletic Lettering
Fabric letters and numbers are cut and sewn onto garments. Used by professional sports teams.
Process:
- 1.Twill fabric laser cut to shape
- 2.Pieces layered if multi-color
- 3.Zig-zag stitched to garment
- 4.Multiple passes for durability
- 5.Steam pressed flat
Pros:
- • Professional sports look
- • Extremely durable
- • Premium 3D appearance
- • Can be repaired
- • Best for team uniforms
Cons:
- • Most expensive option
- • Limited to simple shapes
- • Adds weight to garment
- • Time-consuming process
Ideal For:
- • Professional jerseys
- • Varsity jackets
- • Premium team uniforms
- • Championship gear
- • Letterman jackets
Not Recommended For:
- • Complex logos
- • Budget projects
- • Lightweight fabrics
- • Rush orders
Cost Breakdown:
Which Printing Method Should You Choose?
What type of garment?
Best quality, durability, and value
Sublimation won't work on cotton
Professional look, good durability
How complex is your design?
Most cost-effective
Unlimited colors needed
Premium appearance
What's your quantity?
No minimums required
Good balance of cost/quality
All methods cost-effective
Special Effects & Advanced Techniques
Metallic Printing
Shiny gold/silver finish
+$2 per piece
Glow-in-Dark
Glows in darkness
+$2 per piece
Puff Printing
Raised 3D texture
+$3 per piece
Reflective
Reflects light for safety
+$4 per piece
Glitter
Sparkle effect
+$3 per piece
Distressed/Vintage
Worn, aged look
+$1 per piece
Care Instructions by Printing Method
Sublimation
- Machine wash any temperature
- No special care needed
- Will never fade or peel
Screen Print
- •Turn inside out
- •Wash cold
- •Avoid harsh detergents
DTG
- •Wash inside out
- •Cold water only
- •Air dry preferred
Embroidery
- Normal washing fine
- •Avoid snagging
- •Iron on reverse
Heat Transfer
- •Cold wash only
- •No fabric softener
- •Low heat drying
Combining Multiple Methods
Sublimation + Embroidery
POPULARFull design jersey with embroidered badge
Example: Soccer jerseys with embroidered crest
Screen Print + HTV
COMMONTeam logo with individual names/numbers
Example: Basketball uniforms
DTG + Embroidery
Complex back design with premium front logo
Example: Corporate event shirts
Sublimation + Tackle Twill
PROAll-over pattern with pro numbers
Example: Professional football jerseys
Printing Method FAQs
Which method lasts the longest?
Sublimation and embroidery are lifetime durable. Tackle twill also lasts forever with proper care.
What's the cheapest method for 100 shirts?
Screen printing becomes most economical at 100+ pieces, especially for 1-2 colors.
Can you print white on black shirts?
Yes, screen printing and HTV work great. DTG needs white underbase. Sublimation cannot.
Which method is most eco-friendly?
DTG uses water-based inks. Sublimation has no waste. Both are eco-friendly choices.
What's best for athletic performance wear?
Sublimation - no added weight or texture, fully breathable, moisture-wicking preserved.
Can I get samples of each method?
Yes, we offer sample packs showing all methods on different fabrics for $50.
Still Not Sure Which Method to Choose?
Our printing experts will analyze your project requirements and recommend the perfect method for your needs and budget.