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A sublimated jersey is a polyester sports shirt whose design has been dyed into the fibres rather than printed on top of them. The artwork is printed with disperse dyes on transfer paper, and under heat and pressure the dye turns into a gas that enters the polyester, so the design adds no layer of its own and cannot crack or peel.
This is why sublimation is the usual route for full-print jerseys and event shirts: the whole garment can carry a design, in any number of colours, and the fabric keeps its feel, stretch and ventilation.
How the dye gets into the fabric
Sublimation dyes are made for polyester. When the paper and fabric are pressed together at high temperature, the polyester fibres open slightly and take in the dye vapour; as they cool, the dye is held inside the fibre. The colour is part of the yarn, not a coating on it.
Voyager Sportswear cuts the jersey panels first, transfers the artwork onto each cut panel and then sews the jersey, as described in how a custom sublimated jersey is made. A repeating pattern can instead be printed on the fabric by the metre before cutting. In both routes the dyeing happens before the garment is sewn, so the design continues across seams as long as the artwork was placed for the pattern pieces.
How to recognise a sublimated jersey
| Check | Sublimated jersey | Print applied on top |
|---|---|---|
| Touch | The printed and unprinted areas feel the same | The print feels smoother, heavier or raised |
| Edges | No visible edge between design and fabric | A film, ink or stitch edge around the motif |
| Inside | A paler version of the design on the reverse | Plain fabric behind the print |
| Stretch | Colour stays, with small light specks if stretched hard | Ink or film can crack or lift when stretched hard |
| Coverage | Design can cover the whole shirt, collar and sleeves | Usually placed as separate motifs |
The light specks under strong stretch are the less dyed insides of the knit loops opening up; how much they show depends on the fabric structure.
What sublimation suits
Sublimation suits designs that would be expensive or heavy as an applied print: gradients, photographs, fine patterns, stripes that run across the body and sleeves, and sponsor logos placed in the artwork. The number of colours makes no difference to the printing itself, because every colour is printed in one pass. Numbers can be part of the artwork too; size breakdowns and numbering explains when that makes sense.
Because the print adds nothing to the surface, a mesh or bird's-eye fabric stays as open as it was, and a lightweight race shirt stays light. For bulk orders the print file is the reference for every piece, so the design can be produced again from the same file, with colour checked against the approved sample as described in approving colour.
What the fabric and artwork need
- Polyester. The dye bonds with polyester. On a blend, only the polyester part takes the colour, so the print looks paler as the share of other fibres rises.
- A white or light base fabric. Sublimation dye is transparent and cannot print a colour lighter than the fabric. White in the design is the unprinted fabric, so a dark jersey with a white logo is printed as a dark design with the logo left open.
- Artwork made for the pattern. Each panel needs its artwork set to the panel shape with enough bleed at the seams, and each size has its own panel sizes.
If a design needs a white or light mark on a dark garment, or a raised or textured finish, sublimation is combined with another method such as DTF, heat transfer or embroidery. Choosing sublimation, DTF, heat transfer or embroidery compares them.
Voyager Sportswear makes sublimated jerseys in bulk in Turkey, from 100 pieces per style.
Questions and answers
Can a cotton shirt be sublimated?
No, not with a lasting result: sublimation dye bonds with polyester, and on cotton most of it washes out. On a cotton and polyester blend only the polyester part holds the colour, so the design looks faded in proportion to the cotton share. For cotton garments, DTF, heat transfer or embroidery is used instead.
Can the print on a sublimated jersey crack or peel?
A sublimated print cannot crack or peel, because it is not a layer on the fabric: the dye is inside the polyester fibres. Colour can still change over time through abrasion, strong sunlight, chlorine or harsh washing, and how well it holds depends on the dyes, the fabric and the care. Applied parts on the same jersey, such as a pressed-on number or an embroidered crest, age in their own way.
How can you tell whether a jersey is sublimated?
Run a hand across the design: on a sublimated jersey the printed and unprinted areas feel the same and there is no edge around the motif. Turn the shirt inside out and the design shows faintly on the reverse. A design that covers the whole garment, including collar, sleeves and side panels, is almost always sublimated, while a raised or glossy motif with a clear edge is an applied print.
