Every custom sportswear order comes down to one early decision: how will the design go on the garment? The three most common methods are sublimation, screen printing and embroidery. Each one suits a different fabric, budget and look. Here is how to choose.
Sublimation printing
Sublimation uses heat to turn ink into gas, which bonds with polyester fibers. The design becomes part of the fabric, so it cannot crack, peel or fade the way a surface print can.
- Best for: soccer, basketball and cycling jerseys, and any all-over or multi-color design.
- Fabric: polyester or high-polyester blends, on white or light base fabric.
- Good to know: the number of colors does not change the price, so gradients and complex patterns cost the same as simple ones.
Screen printing
Screen printing pushes ink through a mesh stencil onto the fabric, one color at a time. It gives bold, solid colors and works on cotton, which sublimation cannot do.
- Best for: cotton t-shirts, hoodies and simple logos with one to four colors.
- Fabric: cotton, cotton blends and dark fabrics.
- Good to know: each color needs its own screen, so designs with fewer colors cost less, and the price per piece drops as the quantity goes up.
Embroidery
Embroidery stitches the design into the garment with thread. It has a raised, premium feel and lasts as long as the garment itself.
- Best for: polo shirts, jackets, caps, tracksuits and club crests.
- Fabric: medium and heavy fabrics that can hold stitches without puckering.
- Good to know: cost depends on stitch count, so small, clean logos work best. Very fine text and gradients do not stitch well.
Quick comparison
| Method | Best fabric | Best design | Feel |
|---|---|---|---|
| Sublimation | Polyester | All-over, many colors | No feel, part of the fabric |
| Screen printing | Cotton and blends | Bold logos, few colors | Slight ink layer |
| Embroidery | Medium to heavy fabrics | Small logos and crests | Raised and textured |
Can you combine them?
Yes, and many brands do. A common setup is a sublimated jersey body with an embroidered club crest, or a screen-printed hoodie with an embroidered chest logo. At Villgro Wears, sublimation, embroidery and stitching are all done in-house, so mixed-method orders stay under one roof and one quality check.
Which method for which product?
Most of the decision comes down to the product and the fabric. Here is what we usually recommend to brands and teams in the USA:
- Soccer, basketball and volleyball uniforms: sublimation, so names, numbers and sponsor logos never crack or peel. See our custom team uniforms.
- Cycling jerseys and bib shorts: sublimation for the all-over design, sometimes with a silicone-printed logo on the shorts.
- Compression wear and leggings: sublimation for patterns, or heat transfer and silicone print for a single logo on stretch fabric.
- Cotton T-shirts and hoodies: screen printing for the main graphic, often with a small embroidered logo for a premium touch.
- Polo shirts, jackets and tracksuits: embroidery for crests and chest logos.
What affects the cost of each method?
When you order in bulk, a few factors drive the price per piece more than the method itself:
- Sublimation: the fabric and the garment cut. The number of colors does not change the price.
- Screen printing: the number of colors and print positions, since each color needs its own screen.
- Embroidery: the stitch count, which depends on the logo size and detail.
- Quantity: our minimum is 50 pieces per style and color, and the price per piece drops as quantities grow.
Durability and washing
Sublimated designs last as long as the garment because the ink is part of the fiber. Screen prints hold up well when cured correctly, but heavy ink layers can crack over many washes on stretch fabric. Embroidery is the most durable of all, but it adds weight, so it is not ideal on lightweight performance jerseys.
Learn more about our in-house sublimation printing and embroidery and branding services.
Ready to start? Send us your design, sketch or reference photo through our quote form and our Sialkot team will reply with pricing, MOQ and a sample timeline.