Sublimated Jerseys vs. Screen Printing vs. Tackle Twill: Which Is Best for Your Team?
When you order custom team jerseys, one decision affects the look, the comfort, the price and how long your uniforms last: how the design gets onto the fabric. The three main options are sublimation, screen printing and tackle twill (stitched letters and numbers). Here is a plain-English comparison so you can pick the right one for your team.
What are sublimated jerseys?
Sublimation prints your design onto special paper, then heat-presses it into polyester fabric. The heat turns the ink into a gas that bonds with the fibers, so the design becomes part of the fabric itself instead of sitting on top.
That means:
- No cracking, peeling or fading, even after a full season of washing
- Unlimited colors and designs (gradients, patterns, photos, camo, skylines) at no extra cost
- Names and numbers printed in the same step, so personalization is included
- Lightweight and breathable, because there is no heavy ink layer or stitching
Sublimation works on light-colored polyester, which is exactly what most performance uniforms are made from. It is the standard for modern basketball, football, 7v7, baseball, softball and cheer uniforms.
What is screen printing?
Screen printing pushes ink through a stencil (a screen) onto the garment, one color at a time.
- Great for simple designs with one to three colors
- Works on cotton and blends, so it is popular for T-shirts and spirit wear
- Each extra color needs another screen, so complex designs cost more
- Thick ink on athletic fabric can feel heavy and may crack over time
What is tackle twill?
Tackle twill is the classic stitched look: letters and numbers are cut from twill fabric and sewn onto the jersey.
- Premium, traditional appearance (think classic baseball and hockey jerseys)
- Very durable when done well
- Heaviest and least breathable option
- Most expensive, because every letter and number is cut and stitched by hand
Many teams combine methods: a sublimated jersey body with a tackle-twill chest logo, for example.
Side-by-side comparison
- Design freedom: Sublimation unlimited, screen printing limited by color count, tackle twill limited to letters, numbers and simple logos
- Durability: Sublimation excellent (never peels), screen printing good (can crack), tackle twill excellent (stitching can loosen after years)
- Comfort: Sublimation lightest, screen printing medium, tackle twill heaviest
- Cost for a full custom design: Sublimation usually the best value, screen printing rises with each color, tackle twill highest
- Best for: Sublimation for game uniforms in any sport, screen printing for fan shirts and spirit wear, tackle twill for traditional baseball and varsity looks
Which should your team choose?
- You want a bold, modern design or many colors: choose sublimation.
- You are on a budget but still want full customization: sublimation, because names, numbers and colors do not add cost.
- You want a heritage, old-school look: tackle twill, or sublimation with a twill crest.
- You are making cotton fan T-shirts: screen printing.
What about embroidery?
Embroidery stitches your logo directly into the garment. It is the best choice for coaches’ polos, jackets, hats and bags, where a raised, premium logo looks sharp and lasts for years. At Sigma Sports 21 we offer both sublimation and embroidery, so your game uniforms and your coaches gear can match.
Caring for sublimated uniforms
- Wash inside out in cold water
- Skip bleach and fabric softener (softener blocks moisture-wicking)
- Hang dry or tumble dry low
- Do not iron directly on the design
Follow those steps and sublimated uniforms keep their color for several seasons.
Not sure which method fits your design?
Send us your logo and ideas and we will recommend the best option, then send a free mockup so you can see exactly how it will look.
Get a free quote and mockup for your team
Tell us your sport, colors and roughly how many players you have, and upload your logo or roster right in the form. We reply within 24 hours with pricing and a free design mockup. Request a free team quote or call/text us at (346) 441-7876. We ship to all 50 states, and orders of $300+ get free shipping and 10% off.
