· 4 min read
Sublimation vs Screen Printing vs Embroidery: Choosing the Right Decoration for Team Kit
The decoration method determines how your kit looks, feels, lasts and costs. A practical comparison of sublimation, screen printing and embroidery — and which to choose for uniforms, hoodies and caps.
Updated
In short
The decoration method determines how your kit looks, feels, lasts and costs. A practical comparison of sublimation, screen printing and embroidery — and which to choose for uniforms, hoodies and caps.
The short answer: use sublimation for polyester sportswear (unlimited colour, zero handfeel, never cracks — and names, numbers and sponsors cost nothing extra), screen printing for bold graphics on cotton (hoodies, tees), and embroidery for premium small-area branding (crests, caps, jacket chests). Most serious team and brand orders combine at least two.
Sublimation: the team kit default
Dye-sublimation turns solid ink into gas that bonds into polyester fibre. The design isn't on the fabric; it becomes part of it.
- Feel: none — the fabric stays exactly as breathable and stretchy as undecorated cloth.
- Durability: the design cannot crack, peel or wash out. It outlives the garment.
- Colour: unlimited, including gradients and all-over prints, at no extra cost per colour.
- The killer feature for teams: every shirt in the run can be different — names, numbers, even sponsor variations — with no per-name surcharge, because each piece is printed individually before cutting.
- Limits: polyester (or high-poly blends) only, and light base fabrics work best. You can't sublimate a black cotton hoodie.
This is why virtually all modern team uniforms are fully sublimated, and why sublimated kit MOQs run as low as 10 pieces — there are no screens or dies to set up.
Screen printing: bold graphics on cotton
Screen printing pushes plastisol or water-based ink through a mesh stencil onto the fabric surface. It's the standard for streetwear and merch.
- Feel: a tangible ink layer. High-density and puff inks make this a feature — raised, textured prints that photograph beautifully.
- Durability: very good when cured properly; will eventually crack on high-stretch placements or after hundreds of washes.
- Colour: each colour is a separate screen and a separate setup cost — a 1-colour chest logo is cheap, an 8-colour back piece isn't. Cost per unit falls steeply with quantity.
- Best for: cotton and cotton-blend hoodies, tees and joggers with designs up to a few colours.
On a 25-piece streetwear run, screen setup is why single-colour or two-colour designs are the smart launch move.
Embroidery: the premium signal
Embroidery stitches the design in thread, digitised from your artwork.
- Feel & look: dimensional, textured, unmistakably premium. It reads as "established brand" in a way print doesn't.
- Durability: effectively permanent — it outlasts every print method.
- Cost driver: stitch count. A 10,000-stitch chest crest costs the same on piece 1 and piece 10,000 (after a one-time digitising fee); a full-back embroidery is prohibitively dense.
- Limits: fine gradients and small text don't translate to thread. Below ~4mm letter height, detail disappears. Heavy embroidery needs a stable fabric or backing — it puckers lightweight tees.
- Best for: crests on uniforms and polos, cap fronts, varsity jacket chests, hoodie hits.
Quick decision table
| Scenario | Method |
|---|---|
| Football / basketball / cricket kit with names & numbers | Sublimation |
| Heavyweight hoodie, 2-colour logo, 25–100 pieces | Screen print |
| Club polo with crest | Embroidery |
| Varsity jacket | Embroidery + chenille patches |
| Gym rash guards, all-over design | Sublimation |
| Caps and beanies | Embroidery |
| Retail tee with photographic print | Screen print (or DTG for tiny runs) |
Combining methods
The best kits usually mix: a sublimated match jersey with an embroidered crest; a screen-printed hoodie with an embroidered sleeve hit; a tracksuit with embroidered chest and printed back. Because we run all three decoration methods in-house, mixing doesn't multiply vendors or lead times — it's specified per placement in your quote.
Frequently asked questions
Which method is cheapest?
At team-kit quantities on polyester: sublimation, because setup is digital. On cotton at 25–100 pieces: screen printing for 1–2 colours. Embroidery is priced by stitch count, not colours — small dense logos are cheap, large areas are not.
Which lasts longest?
Embroidery, then sublimation (both effectively lifetime), then screen printing (very good, but the ink layer ages first).
Can you match our existing kit?
Yes — send photos or a physical shirt and we'll match the design and decoration method, or upgrade it (many clubs move from printed names to sublimated kit at reorder and save money doing it).
Specifying kit for the new season? Request a quote with your artwork and quantities — we'll recommend the right method per placement, with pricing, within 24 hours.
