Sublimation vs screen printing vs tackle twill: which is best for team jerseys?

The quick comparison

Sublimation: the default for modern team uniforms

Dye sublimation prints your design onto transfer paper, then heat and pressure turn the ink into a gas that bonds with polyester fibers. Because the color becomes part of the fabric, there is nothing on the surface to crack, peel or wash off. Mesh panels stay breathable and the jersey weighs the same as an undecorated one.

The biggest advantage for teams is design freedom: stripes, gradients, camo, sponsor logos and player names are all printed in one pass, so a complex design costs the same as a simple one. That is why basketball uniforms, soccer kits and hockey jerseys at Gallian are fully sublimated with names and numbers included.

Limitations: sublimation only works on polyester, and it cannot print true white onto a dark fabric (the white areas are left undyed, which is why sublimated garments start as white fabric).

Screen printing: cheap for simple designs on cotton

Screen printing is ideal for one- or two-color logos on cotton tees and hoodies. Every extra color needs its own screen, so multi-color designs get expensive quickly. On stretchy performance fabric, thick plastisol ink can crack over a season, which is why it is rarely used for game uniforms.

Tackle twill: the classic stitched look

Tackle twill letters and numbers are cut from twill fabric and stitched around the edges. It gives the raised, premium look of pro hockey, baseball and football jerseys. It is heavier and costs more: at Gallian, tackle twill adds $6 per garment and embroidery adds $4. Many teams combine both: a sublimated body with tackle-twill numbers.

Which should your team choose?

• Game uniforms for fast sports (basketball, soccer, 7v7, lacrosse, volleyball): sublimation.
• Hockey, baseball and football where you want a traditional look: sublimated body plus tackle-twill numbers or crest.
• Fan shirts, practice tees and fundraisers on cotton: screen printing.

How each method holds up after a season

Durability is where the three methods differ most. Picture a team washing its jerseys after every game for a 25-game season.

• Sublimated jerseys look almost the same at the end of the season. Because the ink is inside the fiber, there is no edge to lift and no surface layer to crack. Colors can soften slightly over many seasons, but the design stays sharp.
• Screen-printed numbers on stretchy fabric often show fine cracks by mid-season, especially on large back numbers that flex every time a player moves. Hot dryers speed this up.
• Tackle twill survives well, but the stitching around the edges can loosen or fray after rough play or many washes, and the twill layer makes the jersey heavier when wet.

Cost at different team sizes

Price depends on the method and how complex the design is:

• Screen printing charges by the number of colors and screens. A one-color logo is cheap, but a full design with numbers, names and stripes needs many screens and print passes.
• Sublimation costs the same whether the design has one color or twenty, because the whole garment is printed at once. For full team uniforms this is usually the lowest total cost.
• Tackle twill adds cost for every letter and number that is cut and sewn. At Gallian it is $6 more per garment, and embroidery is $4 more.

Which method each sport usually uses

Caring for each type of jersey

• Sublimated: wash cold, inside out, and hang dry. Do not iron directly on the print.
• Screen printed: wash cold, inside out, and never tumble dry on high heat.
• Tackle twill: wash inside out on a gentle cycle and let it air dry so the stitching stays tight.

Can you combine methods?

Yes, and many of the best-looking uniforms do. A common setup is a sublimated jersey body with stripes and sleeve graphics, a tackle-twill crest on the chest, and sublimated names and numbers on the back. You get the classic stitched look where it shows most, while keeping the jersey light and the cost under control.

Not sure? Ask for a free mockup and we will show your design in the method that suits it best, or read what custom hockey jerseys cost.

Frequently asked questions