What is Sublimation? A Guide to Pro-Quality Custom Sports Kits

The Essence of Sublimation Printing

If you have ever wondered how sports teams get their colourful designs on jerseys, the answer is dye-sublimation. This modern printing method has become the gold standard for custom sports kits, and for good reason. The result is a sublimation print, known for its durability and vibrancy, making it ideal for sports apparel and merchandise.

But what is sublimation printing, and why is it so much better than the printing on an old-fashioned cotton T-shirt? This guide explains everything you need to know. The dye sublimation process uses heat to transfer dye onto materials, creating long-lasting and vivid images that won't crack or fade.

The Simple Answer: Printing Into the Fabric, Not On It

Dye-sublimation is a digital printing method, also known as dye sublimation printing. It uses heat and pressure to transfer sublimation dye into the fibers of fabric, fusing the dye at a molecular level.

Think of it this way:

• Traditional Printing (like Screen Print): Pushes a layer of ink on top of the fabric, like paint on a wall. You can feel it, it can crack, and it blocks the fabric’s pores. Unlike sublimation, screen print methods do not bond with the fabric and are more prone to wear and fading.
• Sublimation Printing: The sublimation printing process works by turning solid sublimation dye into a gas that, under heat and pressure, fuses with the fabric at a molecular level. This results in a sublimation print that is permanent and becomes part of the fabric itself. It adds zero weight, you cannot feel it, and it keeps the fabric 100% breathable.

In sports, this means your club’s logos, sponsor branding, patterns, and player numbers are all part of the material. The sublimation print will never crack, peel, or fade.

What Equipment is Needed for Sublimation?

Sublimation is a specialized process that requires a specific set of tools to achieve professional results.

• Sublimation Printers: These are not standard inkjet printers. They are built specifically to handle specialist sublimation dyes and print heads that capture every detail of a design.
• Sublimation Inks: These are the special solid dyes that can turn into a gas when heated.
• Transfer Paper: This is a special coated paper designed to hold the ink in place and then release it perfectly onto the fabric under heat.
• A Heat Press: This is the most critical piece of equipment. A commercial heat press delivers the precise combination of high temperature and firm, even pressure needed to trigger the gas-infusion process.
• Design Software: Professional artwork is key. Designers use tools like Adobe Illustrator and Photoshop to create the high-resolution graphics, patterns, and logos that ensure a sharp, professional finish.

The Sublimation Printing Process: A Step-by-Step Breakdown

The “magic” of sublimation is a chemical process. It gets its name from sublimation—when a solid turns directly into a gas, skipping the liquid phase.

This printing technique relies on specialized equipment to produce high-quality, durable prints. The process uses an inkjet printer to print designs onto transfer paper using sublimation inks. This method stands out from screen printing or direct-to-garment by allowing for vibrant, long-lasting designs on polyester or polymer-coated surfaces.

Step 1: Digital Design and Printing

First, your complete kit design—including every logo, color, and number—is finalized on a computer. This is where your club's creativity comes in. Using an online kit builder, you can visually design your own kit from scratch, placing logos, choosing patterns, and testing color combinations in real-time.

Once this digital file is finalized, it is printed onto the special, heat-resistant transfer paper using the specialist sublimation inks.

Step 2: Preparation of the Fabric

The process must use polyester or a polymer-coated material. For sports kits, this is perfect, as 100% polyester is the ideal fabric for performance, wicking sweat, and durability. Sublimation also works well on polyester blends, but it is not suitable for 100% natural fibers like cotton. The fabric pieces (e.g., the front panel, back panel, and sleeves of a shirt) are cut to size and are typically white.

Step 3: The Heat Press Transfer

The printed transfer paper is placed onto the white fabric pieces. They are then fed into a large commercial heat press. This machine applies two crucial things simultaneously:

• Intense Heat (approx. 180-210°C / 350-400°F)
• Precise, Firm Pressure

Improper handling during this stage can cause 'white creasing', which results in unprinted white areas where the transfer paper was creased or folded.

Step 4: The Molecular Infusion

This is where the science happens. The heat and pressure cause two things to happen at once:

1. The special inks on the paper turn from a solid into a gas.
2. The pores of the polyester fabric open.

The gas is drawn into the open fabric pores. As the press is released and the fabric cools, the ink becomes solid again. However, it is now permanently trapped inside the fibers. The design is now a permanent, durable part of the fabric.

Sublimation vs. Other Methods: A Clear Comparison

Understanding why sublimation is the best choice for teamwear is easier when you compare it to other methods, such as screen printing or direct-to-garment printing. While sublimation excels on polyester, other materials like ceramic mugs can also be sublimated if they have a special polymer coating.

Sublimation vs. Screen Printing

• Screen Printing is a traditional method that pushes a thick ink on top of the fabric through a mesh stencil.
• Feel: You can feel the design. It is often heavy and inflexible, especially with large logos.
• Breathability: Poor. The ink layer clogs the fabric’s weave, trapping sweat and heat.
• Durability: Prone to cracking, peeling, and fading after many washes.
• Design: Limited. Each new color requires a new, separate screen, making complex, multi-colored designs extremely expensive.
• Sublimation:
• Feel: You can’t feel the print at all. It's perfectly smooth, soft, and lightweight.
• Breathability: 100%. The fabric’s technical, moisture-wicking properties are completely unaffected.
• Durability: Permanent. A sublimation print bonds the design into the fibres, making it last as long as the garment.
• Design: Unlimited. You can have any design, with any number of colors, gradients, or even photographic images, all for one price.

Sublimation vs. Heat Transfer Vinyl (HTV)

• Heat Transfer Vinyl (HTV) is what’s typically used for individual names and numbers on shop-bought replica shirts. A machine cuts the design from a sheet of vinyl (a type of plastic), which is then heat-pressed on top of the garment.
• Feel: A distinct, often stiff plastic layer.
• Breathability: Zero. The vinyl patch is a non-breathable piece of plastic.
• Durability: The most likely to fail. HTV is notorious for peeling, bubbling, and cracking, especially if put in a tumble dryer.
• Sublimation:
• Feel: Zero feel, zero extra weight.
• Breathability: 100% breathable, even where numbers and names are.
• Durability: Permanent.

The 5 Core Benefits of a Sublimated Sports Kit

This method is the top choice for athletes and teams for these simple, performance-driven reasons:

1. Unmatched Durability: The design is fused with the fabric. You cannot wash it out, crack it, or peel it off. It’s built to withstand tackles, slides, and endless wash cycles.
2. Total Breathability & Performance: Because the ink is in the fibers, it doesn’t block the fabric’s technical weave. This means moisture-wicking and cooling properties work at 100% capacity.
3. Lightweight “Zero-Feel”: There is zero extra weight from the design, no matter how complex. This is essential for athletic performance where every gram matters.
4. Unlimited Design Freedom: This is a huge advantage for clubs. Your team can choose any design, from simple stripes to complex gradients, club watermarks, or photos, all for the same price. All logos are included, so there are no extra fees for adding sponsors.
   This total design freedom allows teams to create truly unique identities. You aren't limited to a pre-made catalogue. From grassroots football clubs to university rugby teams, you can explore a full range of custom sports kits to see what's possible. Whether you need a fully custom football kit, a bespoke rugby kit, or professional teamwear for any sport, the sublimation process ensures your vision comes to life exactly as you designed it.
5. Vibrant, Professional Look: The colours are exceptionally bright, and the print quality is razor-sharp. Sublimation shirt printing delivers high-quality prints that are both vibrant and durable, giving your grassroots team a professional look that lasts all season.

Are There Any Limitations to Sublimation?

To provide a complete picture, it’s important to know the two main limitations of the process. A sublimation print cannot be achieved on 100% cotton or other natural fibers, as the dye only bonds with polymers.

Fabric Requirement: Polyester Only

The chemical bonding process only works with polymer-based materials. This means sublimation is perfect for 100% polyester sportswear but does not work on natural fibers like 100% cotton. It will work on polyester blends, but the vibrancy will be reduced on any non-polyester fibers.

Colour Requirement: White or Light Base

Sublimation is a dyeing process, not a painting one. It adds colour. This means you cannot print a white logo onto a black shirt with sublimation (you can’t dye something black to white). Sublimation does not use white ink, so printing on dark fabrics is not possible. The process must start with white or exceptionally light-coloured fabric to achieve true, vibrant colors.

Frequently Asked Questions

Is sublimation printing eco-friendly?

Compared to traditional dyeing methods that use and pollute huge amounts of water, yes. Sublimation is a “dry” process and uses water-based, non-toxic inks. The use of dry inks also reduces waste. The transfer paper is also often recyclable, making it a more environmentally-conscious choice.

Can you sublimate on a dark-colored shirt?

No. Sublimation ink is translucent. If you print on a dark-colored shirt, the design will not be visible or its colors will be completely distorted by the base color. All sublimated garments must start as white material.

How should I wash a sublimated kit?

You can wash it just like any other sports kit. It is perfectly safe in a standard wash (30-40°C) and can be tumble-dried on low heat. The design will not be damaged.

Conclusion: Is Sublimation Right for Your Team's Kit?

For any team—from local grassroots clubs to professional-level organisations—the answer is yes.

If you want a kit that is light, breathable, and looks good all season, choose sublimation. It offers unmatched durability and complete design freedom, giving you a truly custom and professional-grade product.