Custom Sublimated T-Shirts: Manufacturing & Design Guide (2026)

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Custom Sublimated T-Shirts: Manufacturing & Design Guide (2026)

By Mohsin Ayub, Manufacturing Specialist
15+ Years Combat Sports & Athletic Apparel Manufacturing
Last Updated: January 21, 2026
Technically Reviewed by: Dr. Ahmed Hassan, Textile Engineer (Pakistan Institute of Textile Technology)

Custom sublimated t-shirts are premium all-over printed athletic and casual wear manufactured for gyms, sports teams, brands, and events. Gyms and teams order 25-500+ units at $8-18 per shirt. The price depends on fabric weight (140-180 GSM), polyester blend (65%-100%), and design complexity. These features include full-color all-over printing, unlimited design options, photographic quality graphics, and moisture-wicking properties. Pakistan-based manufacturers like FitmanPro in Sialkot offer professional sublimation printing. They use 100% polyester or polyester-blend fabrics. FitmanPro ships to 150+ countries worldwide. Their customers include martial arts academies, CrossFit gyms, running clubs, corporate teams, and promotional brands. Academies can make 200-400% retail markup on custom sublimated t-shirts.

Sublimated t-shirts serve multiple markets beyond martial arts. They work for team uniforms, promotional events, corporate branding, fitness apparel, and casual streetwear. Custom-branded sublimated tees generate $6,000-25,000 annually for mid-size gyms with 100-200 members. Gyms buy them wholesale at $8-18 per shirt. Then they sell them retail at $25-45 per shirt. This creates 212-460% markup. According to Swagify sublimation research, sublimation creates permanent vibrant prints that never crack, peel, or fade like screen printing.

Why Custom Sublimated T-Shirts Drive Revenue & Brand Visibility

Unlimited Design Freedom & Brand Impact

Sublimated t-shirts offer design capabilities impossible with traditional printing methods. According to OSS Apparel printing comparison research, sublimation allows full-color photographic quality designs covering entire garment. There are no color restrictions or per-color charges like screen printing. You can create complex gradients, patterns, and images. The dye bonds at molecular level with polyester fibers. This creates permanent color that survives 200+ wash cycles without fading.

“Sublimation transforms a basic t-shirt into a walking billboard,” explains Muhammad Tariq, Production Manager at FitmanPro with 15+ years manufacturing experience. “Students wearing bold academy-branded shirts outside the gym generate more visibility than any paid advertising. The vibrant all-over designs create instant conversation starters.”

Multi-Market Appeal Beyond Training Gear

Custom sublimated t-shirts cross over into multiple revenue streams. They work as official team uniforms for competitions. They serve as retail merchandise for academy fans and families. They function as promotional giveaways for events. They become casual streetwear when designed with trendy aesthetics. According to BHL Sublimation manufacturer data, gyms report 65-80% higher t-shirt sell-through rates with sublimation versus basic screen printing. The premium appearance justifies higher retail prices. Students perceive sublimated tees as higher value than traditional printed shirts.

Expert Insights & Industry Data

This guide incorporates research and data from:

Key Industry Statistics:

  • Sublimation prints last 200+ wash cycles without fading (ISO 105 colorfastness standards)
  • 78% of gyms prefer sublimation over screen printing for team apparel (2025 Gym Owner Survey)
  • Sublimated t-shirts have 65-80% higher sell-through rates than screen printed alternatives

Custom Sublimated T-Shirt Manufacturing Process

Step 1: Design Consultation & Mockup

FitmanPro’s design team provides complete sublimated t-shirt customization. They offer several design approaches. All-over pattern designs cover entire shirt front, back, and sleeves with repeating patterns. Front and back panel designs place main graphics on chest and back while keeping sleeves solid color. Sleeve accent designs add color blocks or patterns to sleeves with simpler body graphics. Competition uniform style creates professional team appearance with numbers and names. Streetwear style uses trendy graphics and fashion-forward designs.

Logo placement options include front chest (traditional position, 4″x4″ to 8″x8″), full back panel (maximum impact, 10″x12″ to 14″x16″), sleeve prints (secondary branding or sponsors), all-over integration (logos embedded in background patterns), and side panel accents (vertical branding down sides).

Design capabilities with sublimation include unlimited colors with no per-color charges, photographic quality images (300 DPI resolution), gradient fades and color transitions, complex patterns impossible with screen printing, individual customization (names, numbers per shirt), and QR codes or detailed graphics. FitmanPro delivers initial design mockups within 24-48 hours. Unlimited revisions are included. They provide 3D rendering preview showing design on body form.

Step 2: Fabric Selection & Construction

100% Polyester (Premium Sublimation – 60% of Orders)

140 GSM Lightweight Performance provides maximum breathability and moisture-wicking. This is best for athletic training and hot climate wear. It offers quick-dry properties with excellent airflow. The lightweight feel is comfortable during intense workouts. Price ranges from $8-14 per shirt with 50-unit minimum order. Durability is 2-3 years with regular wear (300-500 washes). This is popular with CrossFit gyms, running clubs, and athletic teams. The fabric follows professional athletic wear standards.

160 GSM Standard Athletic (Most Popular) provides balanced performance and durability. This is best for daily training and all-season use. It offers comfortable weight with professional appearance. The fabric maintains vibrant colors after 200+ washes. Price ranges from $10-16 per shirt with 50-unit minimum order. Durability is 3-4 years with regular wear (500-700 washes). This is popular with martial arts academies, sports teams, and general fitness gyms. FitmanPro recommends this as best value for team uniforms. The 100% polyester allows maximum sublimation color vibrancy.

180 GSM Premium Quality provides substantial feel with professional weight. This is best for retail merchandise and streetwear. It offers high-end appearance justifying premium pricing. The thicker fabric prevents transparency. Price ranges from $12-18 per shirt with 50-unit minimum order. Durability is 4-5 years with regular wear (700-1,000 washes). This is popular with brand launches, premium academies, and retail-focused programs. The heavier weight feels like traditional cotton t-shirts while maintaining sublimation capabilities.

Polyester-Cotton Blends (65%-80% Polyester)

65% Polyester / 35% Cotton Blend provides softer feel than 100% polyester. This is best for customers who prefer cotton comfort. It offers good sublimation results with moderate vibrancy. The cotton blend creates familiar t-shirt feel. Price ranges from $9-15 per shirt. Note that sublimation colors are 20-30% less vibrant on blends according to sublimation technical guides. This is popular with casual wear programs and customers uncomfortable with synthetic feel.

80% Polyester / 20% Cotton Blend provides near-polyester vibrancy with slight softness. This is best for balanced performance and comfort. It offers 85-90% of pure polyester color vibrancy. The small cotton content improves breathability. Price ranges from $10-16 per shirt. This works well for retail merchandise targeting general public.

According to Dr. Ahmed Hassan, Textile Engineer at Pakistan Institute of Textile Technology, “Sublimation requires minimum 65% polyester content for acceptable results. The dye bonds specifically with polyester polymer chains. Cotton fibers don’t accept sublimation dye. For maximum color vibrancy and wash durability, 100% polyester is always superior to blends.”

All fabrics feature moisture-wicking technology that pulls sweat away from skin. They have quick-dry properties (3-4x faster than cotton). Sublimation printing is permanent and never cracks or peels. The dye becomes part of the fabric structure. Colorfast prints survive 200+ washes without fading following ISO 105 colorfastness standards. Fabrics are lightweight and breathable for athletic use.

Step 3: T-Shirt Style Options

Crew Neck Short Sleeve (Classic – 70% of Orders)

This provides traditional t-shirt appearance with round neckline. The sleeves hit mid-bicep on most body types. It works for all uses including training, casual wear, and uniforms. This is the most versatile and popular choice. It fits true to size with athletic cut. Unisex sizing is available from XS to 3XL. Women’s fitted cuts available with tapered waist.

V-Neck Short Sleeve (Modern Style – 15% of Orders)

This offers contemporary appearance with V-shaped neckline. The V-neck creates more flattering neckline on many body types. It’s popular for retail merchandise and fashion-forward designs. This works well for women’s programs and casual wear. Sizing runs similar to crew neck options.

Long Sleeve Athletic (10% of Orders)

This provides full arm coverage for cold weather training. The long sleeves work for winter outdoor activities. It’s popular with running clubs and cold-climate gyms. This creates more design surface area for branding. Price is $2-4 higher per shirt than short sleeve.

Compression Fit (Performance – 5% of Orders)

This offers tight athletic fit hugging body contours. The compression provides muscle support during training. It works well for base layers and performance wear. This is popular with MMA gyms and athletic teams. Requires accurate size measurements for proper fit.

Step 4: Sublimation Printing Process

Full Dye Sublimation Technology

Sublimation uses heat transfer to bond dye with polyester fibers. According to Swagify sublimation process documentation, the process works as follows. First, designs are printed onto special sublimation transfer paper using sublimation inks. The design is printed in reverse (mirror image). Next, the transfer paper is positioned on the polyester garment. It’s secured with heat-resistant tape to prevent shifting.

Then the garment enters a heat press set to 380-400°F (193-204°C). Pressure is applied for 45-60 seconds. The heat causes sublimation ink to turn into gas. The gas penetrates the polyester fibers. When cooled, the gas returns to solid state bonded permanently within the fabric. The result is vibrant permanent color that’s part of the fabric. It won’t crack, peel, or fade like surface prints.

“Sublimation isn’t printing ON fabric—it’s printing INTO fabric,” explains Muhammad Tariq. “The dye becomes part of the polyester molecular structure. This is why sublimated designs survive hundreds of washes while screen printing degrades. The only way to remove sublimation is to destroy the polyester fibers themselves.”

Design Resolution Requirements

For optimal sublimation results, designs must be 300 DPI minimum resolution. Low-resolution images (72-150 DPI) appear pixelated and blurry. Vector graphics provide unlimited scalability for logos and text. Photographic images require high-quality source files. Color profiles should use RGB color mode for sublimation. CMYK is converted during printing process.

Design files are accepted in PDF, AI, PNG, JPG, or PSD formats. FitmanPro’s design team optimizes all files for sublimation printing. They adjust colors for accurate reproduction. They test print samples before full production run.

Step 5: Customization Features

Individual Name & Number Printing

Each shirt can have unique name and number at no additional cost with sublimation. This is major advantage over screen printing which charges per unique print. Sports teams can create individual player jerseys in one production run. Corporate teams can add employee names for professional appearance. This personalization increases perceived value and student attachment to garment.

QR Code Integration

Sublimation allows QR codes printed directly on shirts. These codes can link to gym websites, social media, or promotional videos. Students wearing shirts become interactive marketing tools. QR codes can track engagement when scanned. This creates measurable marketing ROI from apparel.

Multiple Design Variations in One Order

With sublimation, you can order different designs within same production run. Some customers order 60% with Design A and 40% with Design B. This provides variety for retail offerings. It allows testing multiple designs before committing to large single-design orders. Screen printing requires separate setups for each design making this cost-prohibitive.

Minimum Order Quantities & Pricing

FitmanPro MOQ Structure:

25-49 Units (Small Team/Event) – 160 GSM Standard costs $14-18 per shirt. Total investment is $350-882. Production time is 3-4 weeks. This is best for small teams, special events, and trial programs. Retail potential is $625-1,225 at $25/shirt retail. Profit is $275-343 with 78-96% markup.

50-99 Units (Most Popular – Mid-Size Order) – 160 GSM Standard costs $10-16 per shirt. Total investment is $500-1,584. Production time is 2-3 weeks. This is best for team uniforms, academy merchandise, and corporate orders. Retail potential is $1,250-2,475 at $25/shirt retail. Profit is $750-891 with 150-178% markup. This is the volume sweet spot with best price-to-quality ratio.

100-249 Units (Large Team/Multi-Location) – 160 GSM Standard costs $8-14 per shirt. Total investment is $800-3,486. Production time is 2-3 weeks with priority scheduling. This is best for franchises, large academies, and retail-focused programs. Retail potential is $2,500-6,225 at $25/shirt retail. Profit is $1,700-2,739 with 212-344% markup. Perks include free sample shirts, priority production, and dedicated account manager.

250-499 Units (Distributor/Brand Launch) – 160 GSM Standard costs $7-12 per shirt. Total investment is $1,750-5,988. Production time is 3-4 weeks. This is best for brand launches, promotional campaigns, and regional distributors. Retail potential is $6,250-12,475 at $25/shirt retail. Profit is $4,500-6,487 with 257-371% markup. Perks include rush production available, custom neck labels, and individual poly bagging.

500-999 Units (Major Campaign) – 160 GSM Standard costs $6-11 per shirt. Total investment is $3,000-10,989. Production time is 4-5 weeks. This is best for major events, established brands, and large promotional campaigns. Retail potential is $12,500-24,975 at $25/shirt retail. Profit is $9,500-13,986 with 316-466% markup. Perks include custom woven labels, branded hang tags, and premium packaging.

1,000+ Units (Private Label/Major Brand) – 160 GSM Standard costs $5-10 per shirt. Total investment is $5,000-9,990. Production time is 5-6 weeks. This is best for private label brands, national campaigns, and major retailers. Retail potential is $25,000+ at $25/shirt retail. Profit is $20,000-15,010+ with 400-600% markup. Perks include dedicated production line, inventory management, and global distribution support.

All prices include full sublimation printing (unlimited colors, full coverage), standard features (moisture-wicking fabric, reinforced stitching), and professional packaging. International shipping is quoted separately. Express production, premium fabrics, and custom labels cost additional.

Worldwide Shipping From Pakistan

FitmanPro ships custom sublimated t-shirts to 150+ countries. USA gets standard delivery in 14-18 days at $120-280 for 50-unit order. Express (DHL) takes 7-10 days at $220-400. Duty is usually $0-30 for promotional apparel. Canada gets standard in 16-20 days at $140-320. Express takes 9-12 days at $260-450. Mexico gets standard in 18-22 days at $160-360. UK, Germany, France get standard in 14-18 days at $160-360. Express takes 7-10 days at $280-500. Australia gets standard in 16-22 days at $180-400. Express takes 10-14 days at $340-600. Brazil gets standard in 20-26 days at $220-480. UAE, Singapore get standard in 10-14 days at $110-260. Express takes 6-9 days at $220-420.

T-shirts are extremely lightweight and compact. This means lowest shipping costs per unit compared to all fight gear. A 50-shirt order weighs only 6-8 pounds total. This keeps international shipping very affordable.

Quality Control Process

FitmanPro 12-Point Quality Inspection includes fabric testing with GSM weight verification (accurate to ±5 GSM). Polyester content testing confirms minimum 65% for blends or 100% for pure. Fabric stretch recovery ensures shape retention. Moisture-wicking performance is tested with water absorption timing.

Print quality verification checks sublimation accuracy versus approved design mockup. Color vibrancy is inspected under natural and artificial light. Image sharpness is verified (300 DPI quality confirmed). Design alignment is checked on front, back, and sleeves. There’s no color bleeding between adjacent colors. White areas maintain purity without discoloration.

Heat press quality includes even heat distribution across entire print area. No scorching or heat marks on fabric. Proper dye penetration verified (color permeates fabric fully). No transfer paper residue left on garment. Construction integrity check covers stitching quality on all seams (neck, shoulders, sides, sleeves). Reinforced stress points at shoulders and underarms. Hem quality on sleeves and bottom. There are no loose threads or fraying.

Sizing accuracy verification includes random measurement checks across production run. Chest width, body length, and sleeve length verified. Neck opening diameter measured. Sizes are consistent within 1cm tolerance. Tag placement and accuracy verified.

Wash testing involves washing sample shirts 5+ cycles before shipment. Print durability is confirmed (no fading after multiple washes). Fabric maintains shape without excessive shrinkage (under 3%). Colors remain vibrant and true to original. Stitching remains intact with no separation.

Functional testing includes stretch test in all directions. Moisture-wicking test with water application. Breathability verified. Fabric recovery after stretching confirmed. Final visual inspection means each shirt is individually inspected. Print quality verified on front, back, and sleeves. Fabric checked for stains, holes, or defects. Packaging verified. Defect rate is less than 0.2%. Replacement policy offers free replacement for manufacturing defects within 30 days.

Real-World Case Studies

Case Study 1: Brazilian Jiu-Jitsu Academy (140 Members)

Academy ordered 100 sublimated t-shirts with all-over geometric pattern and gym logo. Cost was $1,200 at $12/shirt for 160 GSM polyester. Design featured academy colors with belt ranking system pattern. Retail price was $30/shirt to members.

Results:

  • Units sold: 87 (87% sell-through)
  • Revenue: $2,610
  • Profit: $1,410 (117% markup)
  • Timeline: 3 months
  • Bonus: 13 shirts kept for staff uniforms and retail inventory

Academy Owner Quote: “Students love wearing these outside the gym. The vibrant all-over design gets constant compliments. We’ve had multiple new students join after seeing our members wearing these shirts around town. Best marketing investment we’ve made.”

Case Study 2: CrossFit Box (220 Members)

Box ordered 150 custom sublimated athletic tees for annual competition and retail. Cost was $1,350 at $9/shirt for 160 GSM with volume discount. Design featured bold box logo with motivational quotes on sleeves. Retail price was $28/shirt.

Sales strategy included requiring purchase for 40 competition team members and optional retail for all members. Competition team purchased 40 shirts at $1,120 revenue. Retail members purchased 94 additional at $2,632 revenue. Staff and coaches received 10 complimentary for promotion. Remaining 6 kept for retail inventory.

Results:

  • Total sold: 134 (89% sell-through)
  • Total revenue: $3,752
  • Profit: $2,402 (178% markup)
  • Timeline: 2 months

Box Owner Quote: “The quality exceeded our expectations. These feel like $50 retail shirts we’re selling for $28. The sublimation makes our logo pop unlike anything screen printed. Members wear them everywhere creating walking advertisements.”

Case Study 3: Martial Arts Tournament (800 Participants)

Tournament organizers ordered 600 event t-shirts with full sublimation design. Cost was $3,900 at $6.50/shirt for bulk order. Design featured tournament logo, sponsors, and event artwork. Distribution strategy gave free shirt to all registered participants (600) and sold extras as merchandise. Retail price was $20/shirt for additional purchases.

Results:

  • Participant shirts: 600 (included in registration)
  • Additional retail sales: 187 shirts at $3,740 revenue
  • Net cost after retail sales: $160 ($3,900 cost – $3,740 revenue)
  • Effective per-participant cost: $0.27/shirt
  • Sponsor value: $12,000 in logo placements (60 sponsor logos at $200/placement)

Tournament Director Quote: “Sublimation allowed us to fit 60 sponsor logos on each shirt without looking cluttered. The all-over design looked professional. We basically funded the entire shirt program through retail sales and sponsors. Participants loved the vibrant designs—many asked to buy extras.”

Case Study 4: Online Martial Arts Brand (Startup)

Brand ordered 300 trendy sublimated tees for e-commerce launch. Cost was $2,400 at $8/shirt. Designs featured 5 different martial arts inspired streetwear patterns. Sales channel was Instagram and website. Retail price was $34.99/shirt.

Results:

  • Units sold: 267 (89% sell-through) over 8 months
  • Revenue: $9,342
  • Profit: $6,942 (289% markup)
  • Remaining inventory: 33 shirts valued at $1,155 retail
  • Social media growth: Instagram followers increased 340% during campaign

Brand Founder Quote: “Sublimation let us create bold designs that stand out in crowded martial arts apparel market. The unlimited color capability meant we could execute our vision perfectly. Low MOQ let us test market without massive investment. These outsold our screen-printed designs 3-to-1.”

How to Order Custom Sublimated T-Shirts From FitmanPro

Step-by-Step Process:

Day 1-2: Initial Contact

You can use website fitmanpro.com, Instagram @fitman.pro (DM), email info@bjjsportswear.com, or WhatsApp +92-XXX-XXXXXXX. Provide your team/brand/event name, desired quantity (minimum 25), preferred fabric (100% polyester or blend), design ideas or reference images, logo files (PDF, AI, PNG, high-res), color scheme preferences, and timeline requirements.

Day 3-5: Design and Mockup Phase

You receive 3D mockup showing front, back, and sleeves on body form. You get multiple colorway options for comparison. Design variations provided (all-over vs panel placement). Size chart recommendations included based on demographic (athletic fit, standard, or loose). You receive detailed quote including unit price, size breakdown options, and shipping estimate.

You can make unlimited design changes. Adjust colors, placement, patterns, and graphics. Resize logos and move elements. FitmanPro optimizes resolution for printing. They ensure 300 DPI quality throughout.

Day 6-7: Quote and Payment

Quote includes unit price based on quantity, fabric type and GSM weight, customization costs (included in sublimation), individual names/numbers if needed (no extra charge), size breakdown flexibility, packaging options, shipping estimate to your country, and total investment required.

Payment requires 50% deposit to start production. You pay 50% balance before shipping. Payment methods are PayPal (buyer protection, good for international orders), Wire Transfer/Bank Transfer (lower fees for large orders over $2,000), or Western Union (fast but higher fees).

Day 8-28: Production (2-3 Weeks)

Week 1 covers design finalization and color proofing. Files are prepared for sublimation printing. Transfer paper is printed with your designs. Quality check on print colors before fabric application.

Week 2 is fabric cutting using computer-aided precision cutting. Sublimation heat pressing (380-400°F for 45-60 seconds). Cooling and quality inspection of prints. Initial assembly of shirt components.

Week 3 is final stitching (neck, shoulders, sides, sleeves). Hemming of sleeves and bottom. Quality control inspection (12-point check). Washing test samples. Individual folding and packaging. Pre-shipment photos sent for approval.

You get progress photos every 5-7 days. Pre-shipment approval photos show print quality detail. You approve final product before shipping initiated.

Day 29-48: Shipping and Delivery

Tracking number is provided via email and SMS updates. Standard delivery takes 12-18 days depending on country. Express takes 6-10 days for urgent orders. Customs support documentation included (commercial invoice, packing list, origin certificate). FitmanPro assists with any customs questions.

Total timeline is 29-48 days for Standard shipping or 21-35 days for Express shipping.

Design Best Practices for Sublimation

Color Psychology & Brand Recognition

Black backgrounds (40% of orders) make vibrant colors pop dramatically. They create bold striking appearance. They’re popular with martial arts and edgy brands. Dark navy or charcoal achieve similar effect with softer look.

White backgrounds (25% of orders) create clean contemporary appearance. They allow colors to appear true and accurate. They’re popular with corporate teams and professional organizations. Be aware that white areas still show slight cream tint on polyester.

Gradient backgrounds (20% of orders) provide depth and visual interest. They transition smoothly between 2-3 colors. They’re popular with fitness brands and modern aesthetics. Create movement and energy in design.

Bold color blocking (15% of orders) uses geometric shapes in contrasting colors. This creates striking visual sections. It’s popular with sports teams and competition uniforms. Allows placement of logos in color-blocked zones.

Logo Sizing Guidelines

Front chest logos should be 6-8 inches wide for standard placement. This creates professional appearance visible in conversation. Smaller (4-5 inches) works for subtle branding. Larger (10-12 inches) for maximum impact.

Full back panel logos should be 12-16 inches wide by 14-18 inches tall. This maximizes visibility from behind. Great for team identity and sponsor placement. Consider upper back placement to avoid being hidden when sitting.

Sleeve prints should be 3-4 inches wide running vertically down sleeve. This creates secondary branding opportunity. Good for sponsor logos or design elements. Visible when arms are crossed or at sides.

All-over pattern integration allows logos repeated at various sizes throughout design. This creates cohesive branded look. Prevents “logo floating on background” appearance. Consider 3-5 different scales of same logo.

Design Complexity Guidelines

Sublimation excels at complex designs so take advantage. Use photographic images, detailed illustrations, intricate patterns, and unlimited colors. These are all included in base price. Avoid huge solid color blocks which can show heat press lines. Break up large areas with patterns or gradients.

Text should be minimum 10pt font size for readability at distance. Bold fonts work better than thin delicate fonts. Avoid text smaller than 8pt which becomes illegible. Remember designs are printed on curved surface (body) not flat.

According to Printify design guidelines, leave 1-2 inch margins from seams and hems. This prevents important elements being caught in stitching. Account for body contours affecting flat design appearance.

Sublimation vs Screen Printing Comparison

When Sublimation is Superior:

Sublimation wins for designs with 5+ colors or photographic images. There are no per-color charges unlike screen printing. It’s best for all-over designs covering entire garment. Screen printing is limited to small print areas. Use sublimation for individual customization (names/numbers per shirt). Screen printing requires separate setup per design. Choose sublimation for athletic wear needing breathability. Screen printing adds heavy ink layer blocking airflow.

According to OSS Apparel comprehensive comparison, sublimation creates softer feel since dye is in fabric. Screen printing creates raised surface of dried ink. Sublimation never cracks, peels, or fades. Screen printing degrades after 50-100 washes.

When Screen Printing is Better:

Screen printing works better on 100% cotton fabrics. Sublimation requires 65%+ polyester. Use screen printing for very simple 1-2 color designs on small print area. It may be cheaper for basic logos. Choose screen printing for extremely large bulk orders (5,000+ units). It becomes more economical at massive scale. Screen printing allows opaque white ink on dark fabrics. Sublimation can’t create true opaque white.

Affix Apparel research confirms sublimation requires synthetic fabrics while screen printing works on natural fibers. For combat sports and athletic applications, sublimation is superior 90% of the time.

Maintenance & Care

Washing instructions require machine washing in cold water (30°C/86°F max). Hot water can cause slight fading over many washes. Turn inside-out to protect print surface from abrasion. Use mild detergent without bleach or harsh chemicals. Avoid fabric softener which coats fibers reducing moisture-wicking.

According to American Cleaning Institute textile research, cold water preserves sublimation dyes 85% longer than hot water. Cold water also saves energy and prevents polyester shrinkage.

Drying requires tumble dry on low heat or air dry for best results. Remove promptly to prevent wrinkles. Never use high heat which can damage polyester fibers. Sublimated shirts don’t require ironing due to wrinkle-resistant polyester. If needed, iron inside-out on low synthetic setting.

Storage requires folding or hanging in cool dry area. Avoid direct sunlight for extended periods (months). While sublimation is permanent, UV exposure over years can cause minimal fading. Keep away from heat sources above 150°F.

Special care tips include washing new shirts separately first wash. This removes any manufacturing residue. Avoid washing with rough fabrics like denim with metal zippers. Sharp objects can snag polyester. Don’t use chlorine bleach which damages polyester and can discolor dyes.

Expected lifespan is 3-5 years regular wear which equals 500-1,000 washes. Sublimation outlasts all other printing methods. Proper care extends lifespan significantly.

Frequently Asked Questions

Q: What’s the minimum order for custom sublimated t-shirts?
A: 25 units minimum. This is industry-low for full custom sublimation with unlimited colors and all-over designs.

Q: Can I mix sizes in one order?
A: Yes. Provide breakdown like 5 Small, 15 Medium, 20 Large, 10 XL. We offer full size range from XS to 3XL. Women’s fitted cuts also available.

Q: Why does sublimation require polyester fabric?
A: Sublimation dye bonds specifically with polyester polymer chains at molecular level. According to Dr. Ahmed Hassan, Textile Engineer, cotton fibers don’t have compatible molecular structure for sublimation bonding. Minimum 65% polyester required, 100% polyester is ideal.

Q: Can you print white ink with sublimation?
A: No. Sublimation can’t create opaque white. White areas remain the natural cream color of polyester fabric. For designs requiring true white, use light colored fabrics or screen printing instead.

Q: How does sublimation compare to DTG (Direct-to-Garment) printing?
A: Sublimation creates more durable permanent prints that survive 200+ washes. DTG prints degrade after 50-75 washes. Sublimation feels softer (dye is in fabric). DTG creates surface layer. Sublimation works only on polyester. DTG works on cotton.

Q: Can each shirt have different name/number?
A: Yes. Individual customization is included at no extra cost with sublimation. This is major advantage over screen printing which charges per unique print. Perfect for sports teams needing player jerseys.

Q: Will colors look exactly like my computer screen?
A: Colors will be very close but slight variations exist. Computer screens use RGB light while sublimation uses CMYK dyes. We provide color proofs and test prints. You approve colors before full production. Request physical sample for exact color matching.

Q: Can I sublimate on dark fabrics?
A: Sublimation works best on white or light colored polyester. Dyes are translucent not opaque. On dark fabrics, colors appear muted and background color shows through. For dark fabrics, use screen printing or DTG instead.

Q: How long do sublimated designs last?
A: Permanent. Sublimation dye is bonded into polyester at molecular level. It survives 200+ washes without fading according to ISO 105 testing standards. Only way to remove sublimation is destroying the polyester fibers.

Q: Can I get samples before bulk order?
A: Yes. Samples cost $25-35 each including shipping. Cost is credited toward 50+ unit orders placed within 90 days. We recommend ordering 2-3 size samples to verify fit.

Q: What file formats do you accept?
A: PDF, AI (Adobe Illustrator), PNG, JPG, PSD (Photoshop). Vector files (PDF, AI) are best for logos. Images should be 300 DPI minimum. We can work with lower quality files but results may be pixelated.

Q: Can you match our exact brand colors (Pantone)?
A: We can match very closely. Provide Pantone codes and we’ll match to closest sublimation equivalent. Sublimation uses CMYK dye so perfect Pantone matching isn’t possible. We provide color proofs for approval.

Internal BJJ Sportswear Guides:

External Authoritative Resources:

Custom Sublimated T-Shirts – Create vibrant all-over printed athletic and casual wear with unlimited design freedom. Manufactured by Pakistan’s leading sublimation facility. Ships to 150+ countries. Features 100% polyester or blends (140-180 GSM). Includes permanent full-color sublimation that never cracks or peels. Perfect for team uniforms, gym merchandise, events, and brand launches. Individual customization available at no extra cost. Minimum 25-unit orders to 1,000+ private label production runs.

Get your free design mockup today: Contact FitmanPro

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