Two specifications decide how a custom kit looks after twenty washes: the fabric it is printed on and the way the graphics are applied. This page compares every decoration method we run in house, explains the difference between sublimation, heat transfer and DTF in plain terms, and gives the fabric and GSM we actually use by sport, so you can specify a kit rather than accept whatever arrives.
Decoration methods compared
| Method | How it works | Durability | Best for | Main limitation |
|---|---|---|---|---|
| Dye sublimation | Ink turns to gas under heat and dyes the polyester fibre itself | Lasts the life of the fabric; nothing to crack or peel | Full-colour jerseys, gradients, photo effects, all-over patterns, names and numbers | Polyester only, and light base fabrics |
| Screen printing | Ink is pushed through a mesh stencil onto the surface | Very good with correct curing | Solid one to three colour logos on cotton or blends, larger runs | A screen per colour, so setup cost rises with colours |
| Heat transfer vinyl | Coloured vinyl is cut and heat pressed on | Good; edges can lift if pressed poorly | Numbers, names and simple shapes on small runs | Solid colours only, and a slight hand feel |
| DTF, direct to film | Design is printed onto film with adhesive powder, then pressed on | Good, flexible; sits on the surface | Full colour on cotton, blends and dark fabrics where sublimation cannot work | A visible film edge and a light hand feel |
| Embroidery | Thread stitched directly into the fabric | Extremely durable | Club crests, staff polos, jackets, caps | Not suitable for fine detail, gradients or very light fabrics |
| Twill appliqué | Fabric letters or shapes cut and sewn on | Extremely durable | Baseball lettering, varsity jackets, heritage looks | Adds hand work, so adds cost and lead time |
The difference between DTF, heat transfer and sublimation
These three get confused constantly, and the difference is simply where the colour ends up. In sublimation the ink becomes part of the polyester fibre, so there is no layer on top: you cannot feel the graphic, it cannot crack or peel, and it will not fade the way a surface print does. The trade-offs are that it only works on polyester and only on light base cloth, because you cannot dye a dark fibre lighter.
Heat transfer vinyl is the opposite: a pre-coloured vinyl sheet is cut to shape and pressed onto the garment. It is cheap for a handful of numbers, works on dark fabric, and gives crisp solid colour, but each colour is a separate layer and a badly pressed edge is the classic thing that lifts in the wash. DTF sits between the two. A full-colour design is printed onto a film, coated with adhesive powder, cured, then heat pressed. It gives sublimation-like colour on cotton and on dark garments, which sublimation cannot do, at the cost of a thin flexible layer you can feel and see at the edge.
Practical rule: polyester performance kit, light base, full colour, use sublimation. Cotton tees, hoodies or dark garments with a photographic design, use DTF. A dozen squad numbers on existing dark shirts, use heat transfer vinyl. The longer comparison is in our sublimation vs screen printing vs heat transfer guide.
Which logo method lasts longest on a sports jersey
For a polyester jersey the order is straightforward. Sublimation and embroidery outlast the garment, because one is inside the fibre and the other is thread through it. Screen printing on a correctly cured polyester or cotton garment comes next. DTF is durable but is still a layer. Heat transfer vinyl is last, not because it is bad but because it depends entirely on press quality and on how the team washes the kit. If a supplier quotes a full-colour design as heat transfer on a performance jersey when sublimation is available, ask why.
Fabric and GSM by sport
| Sport or garment | Fabric we use | Typical weight | Why |
|---|---|---|---|
| Soccer jersey | Polyester interlock | 140 to 160 gsm | Smooth uniform surface for sublimation, holds shape after washing |
| Soccer jersey, hot climates | Polyester mesh or bird-eye | 130 to 150 gsm | Maximum airflow, slightly less opaque |
| Basketball uniform | Moisture-wicking breathable polyester mesh | Specify with your quote | Airflow and stretch for repeated sprint and jump loading |
| Baseball jersey | Polyester, with twill lettering where the look matters | Specify with your quote | Button placket and lettering define the sport’s look more than fabric does |
| Rugby jersey | Heavier knit or woven polyester with reinforced seams | 200 to 260 gsm | Contact and shirt-pulling destroy lightweight cloth |
| Polo shirt | Polyester or poly-cotton pique | 180 to 220 gsm | Structure for a collar, and a fabric that looks right off the pitch |
Always give a target GSM in the enquiry. Ask two factories for a heavy fabric and you get two different cloths at two different prices, and the cheaper quote is usually the lighter cloth. Our category detail sits on the soccer, basketball, baseball and polo pages, and the wider fabric discussion is in what is the best fabric for custom team uniforms.
140 gsm or 160 gsm for a team jersey
At 140 gsm the jersey is noticeably lighter and cooler, drapes more and is the right answer for summer football, hot and humid climates, and youth teams who will outgrow the kit within two seasons. At 160 gsm the same interlock is more opaque, holds its shape better through repeated washing, resists snagging and simply feels more expensive in the hand, which matters for a first-team kit or a retail range. If you plan to keep the kit for three seasons, choose 160. If the players complain about heat more than about longevity, choose 140. The price difference between the two on a 50-piece order is small compared with the difference decoration complexity makes.
How Pantone colour matching works
Send Pantone references rather than colour names. We match to Pantone at the printing stage and show the colours on your free digital mockup within 24 hours, and where a club colour is critical we recommend judging it on a physical sample under daylight rather than on a screen, because no two monitors agree. Two honest limits: a colour dyed into fabric can read slightly differently on mesh than on interlock because the surface scatters light differently, and fabric dyed in a later batch can vary very slightly in shade, which is why spares are best ordered with the original run.
Cotton or polyester
Polyester for anything played in. It wicks moisture, dries fast, keeps its shape and is the only fibre that accepts sublimation. Cotton or a poly-cotton blend is for the off-pitch half of the range: supporter tees, staff polos, hoodies and training tops, where comfort beats performance. Cotton cannot be sublimated, so full-colour designs on cotton are DTF or screen printed instead.
Chenille and twill patches
Sewn-on decoration is the traditional look for baseball and varsity styling. We cut and sew twill lettering and appliqué in house, in single or double layer, and chenille patches can be included as a sourced trim when you ask for them at quotation stage. Both add hand work, so confirm them in the quote rather than after approval: they change price and add a few days to the schedule set out on our sampling and lead time page.
Fabrics, weights and decoration methods on this page are those Eliian runs in house in Xiamen, China. Weights given as ranges are our standard offer; where a page says to specify a target GSM, it is because the right weight genuinely depends on climate and level of play. Written 17 August 2026.
Frequently asked questions
What is the best fabric for custom soccer jerseys?
Polyester interlock at 140 to 160 gsm is the default: a smooth surface that takes sublimation cleanly and holds its shape through repeated washing. For hot and humid climates, a polyester mesh or bird-eye at 130 to 150 gsm gives more airflow at the cost of a little opacity. Cotton is not suitable, because it cannot be sublimated.
What is the best fabric for basketball uniforms?
A moisture-wicking, breathable polyester mesh, which is what the great majority of clubs order. Mesh matters more in basketball than in most sports because of repeated sprint and jump loading in indoor heat, and reversible sets change the fabric and pattern together, so decide reversibility before the mockup stage.
Is 140 GSM or 160 GSM better for team jerseys?
140 gsm is lighter and cooler, and suits summer football, hot climates and youth teams who will outgrow the kit. 160 gsm is more opaque, holds shape better through washing and feels more substantial, which suits first-team kit and retail ranges expected to last three seasons. Neither is better in the abstract; the climate and the kit’s expected life decide it.
Is sublimation better than screen printing for team uniforms?
For full-colour polyester kit, yes. Sublimation dyes the fibre itself, so gradients, patterns, names and numbers cost nothing extra and cannot crack or peel. Screen printing is better for solid one to three colour logos on cotton or blends, where each colour needs its own screen and setup cost rises with the number of colours.
How is Pantone color matching handled for teamwear?
Send Pantone references rather than colour names. Colours are matched at the printing stage and shown on the free digital mockup within 24 hours, and a physical sample judged in daylight is the reliable check because monitors vary. The same Pantone can read slightly differently on mesh than on interlock, and later dye batches can vary slightly, so order spares with the original run.
What is the difference between DTF, heat transfer and sublimation?
Sublimation turns ink into gas that dyes the polyester fibre, so there is no layer to feel, crack or peel, but it needs light polyester. DTF prints a full-colour design onto film with adhesive powder and presses it on, which works on cotton and dark garments but leaves a thin flexible layer. Heat transfer vinyl is pre-coloured vinyl cut to shape and pressed on, cheap for numbers and names but limited to solid colours.
Which logo method is most durable on sports jerseys?
Sublimation and embroidery last the life of the garment, because one is dyed into the fibre and the other is stitched through it. Correctly cured screen printing comes next, then DTF, then heat transfer vinyl, which depends most on press quality and washing. On a light polyester jersey a full-colour design should be sublimated rather than transferred.
Can baseball jerseys include chenille or applique patches?
Yes. Twill lettering and appliqué are cut and sewn in house in single or double layer, which is the traditional baseball and varsity look, and chenille patches can be included as a sourced trim if you request them at quotation stage. Both add hand work, so they add cost and a few days to the lead time and should be confirmed in the quote.