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For a custom sublimated jersey, we cut the polyester fabric to the garment pattern first. The artwork is printed on sublimation transfer paper and transferred by heat onto the cut pieces, which are then sewn into the jersey. A repeating design can instead be printed by the metre before the fabric is cut and sewn. The artwork and the production plan decide which route suits the order. What is a sublimated jersey explains the method itself and how to recognise the result.
Custom jerseys: cutting, printing and sewing
- Confirm the garment design, size range and artwork.
- Cut the polyester fabric into the pattern pieces.
- Print the artwork onto sublimation transfer paper.
- Transfer the design from the paper into the fabric with heat.
- Sew the printed pieces into the finished jersey.
The front, back and sleeves can each carry their own design. Club crests, sponsor logos and any numbers can be part of that artwork if they are approved before printing. A large graphic does not mean the fabric has to be printed on the roll.
When a repeating pattern is printed by the metre
A repeating pattern can be transferred onto the continuous fabric before cutting, and the printed fabric is then cut and sewn. This suits a motif meant to repeat across the material. It will not by itself put a crest or number in a set position on each jersey, so those details need their own placement plan.
The design decides the sequence. A pattern that repeats across the fabric and a graphic placed on one garment piece are different artwork jobs, even when the finished shirts look alike.
Prepare artwork for the garment pattern
We need editable logos where you have them, colour references, finished logo dimensions and a front-and-back layout. Mark which graphics keep the same size across the size range and which scale with the garment. If adult and youth sizes are both ordered, a design approved on an adult shirt also has to be checked on the smallest youth size.
Leave room in the artwork for seam allowances, and keep small lettering and important logo details away from seams, neck openings and hems. If a stripe has to run across a seam, tell us before sampling. Cutting accuracy, print placement and sewing all affect the join, and neither printing sequence guarantees an exact match.
Approve colour and placement on a sample
Judge colour on the proposed fabric, not only on a screen or a paper printout. On the sewn sample, check logo size, number legibility and how the placement looks when worn. Front and back pieces can meet correctly when flat and still look different once the garment is assembled.
For numbered kits, approve one controlled number list that links each number to its garment size and quantity, and record the artwork version and approval date. Keep home, away and goalkeeper designs separate so the production team never has to guess which file belongs to which garment.
What happens if a sponsor changes?
Changing sublimated artwork after printing may mean reprinting the affected pieces. A separate transfer can sometimes be added to the finished garment, depending on the fabric, the existing print, the space available and the production schedule, but it is not an automatic fix for a late change.
Tell the factory which logos or numbers are still waiting for approval, and confirm the deadline and method for each open item before the rest of the order is released.
What to send for a quotation
For a quotation we need the jersey reference or design, quantity and size breakdown, fabric requirements, colour references and any number list. Flag any seam-matching details and anything that is not yet final. Voyager Sportswear can review your artwork or discuss design assistance before the sample is developed.
- sportswear production guide
- sublimation, transfers, screen printing or embroidery
- size breakdowns and numbering for bulk jersey orders
- request a quote
Questions and answers
Does a large jersey graphic need roll-to-roll sublimation printing?
A large jersey graphic does not need roll-to-roll sublimation printing. With cut-panel sublimation, the front, back and sleeves can each carry their own design, printed on transfer paper and heat transferred onto the cut polyester pieces before sewing. Printing by the metre suits a motif meant to repeat across the fabric. That route does not place a crest or number on each jersey by itself, so those details need their own placement plan.
Should jersey logos scale with size or stay fixed across a size range?
Jersey logos can keep one size across the range or scale with the garment, and the artwork should show which rule applies to each graphic, with finished logo dimensions and a front-and-back layout. When adult and youth sizes are both ordered, the design approved on the adult shirt also needs checking on the smallest youth size. Small lettering and logo details should stay clear of seams, neck openings and hems.
Can a sponsor logo be added to a finished sublimated jersey?
A sponsor logo can sometimes be added to a finished sublimated jersey as a separate transfer, depending on the fabric, the existing print, the space available and the production schedule. The transfer is not an automatic fix for a late change, and changing the sublimated artwork itself after printing may mean reprinting the affected pieces. Tell the factory which logos are still awaiting approval and agree a deadline and method for each.
