Sublimation vs. Screen Printing: The Ultimate Comparison for Custom Apparel
Today’s customers judge any clothing piece in seconds. They zoom in on online photos, heavily inspect the materials when visiting retail stores, and expect vibrant color that lasts longer than the latest social trends.
Choosing the right printing method can make all the difference. Screen printing and sublimation are two of the most popular choices among brands looking to create high-quality designs.
But which one should you choose for your custom apparel?
Let’s break down screen printing and sublimation in terms of pros, cons, costs, and when to use each method so you can make the best decision for your brand.
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How Screen Printing Works: A Tried-and-True Classic
Screen printing has been the go-to method for custom apparel for decades. It’s a manual stencil-based process where a design is transferred to a mesh screen, and ink is pushed through the screen onto the fabric.
Each color in the design requires a separate screen, which is why the setup process can be more time-consuming and costly for multi-color designs.
Pros of Screen Printing:
Screen printing offers a wealth of benefits, making it a top choice for many apparel brands. Here’s why it might be the perfect fit for your next project.
- Versatility on Various Fabrics: Screen printing can be used on many fabrics, but it’s best on cotton. This makes it an ideal choice if you need to print on a wide range of apparel or promotional items.
- Cost-Effective for Large Runs: Once the setup is done (which can involve creating screens and mixing inks), the per-unit cost for each additional shirt drops significantly.
This makes screen printing highly cost-effective for large batches. For bulk orders, screen printing shines, especially if you’re printing a simple design in a few colors. - Durability: Screen prints, particularly when done with plastisol inks, are incredibly durable and can withstand years of wear and multiple washes. The print sits on top of the fabric, forming a strong bond that resists fading and cracking for a long time.
- Specialty Inks and Effects: Screen printing allows for creativity beyond just color. With specialty inks like puff (for 3D effects), metallics, and glitter, you can achieve unique designs that stand out.
These effects aren’t possible with sublimation, making screen printing ideal for streetwear or merchandise that requires a tactile, elevated feel.
Cons of Screen Printing:
While screen printing offers numerous advantages, it does come with a few limitations that may make it less suitable for certain projects or design needs.
Here are some key drawbacks to consider before moving forward.
- High Setup Costs for Small Runs: Screen printing requires a separate screen for each color, meaning the setup costs can be significant.
If you’re printing a small batch or just testing a design, these initial costs can be hard to justify. Additionally, many print shops have a minimum order requirement, which could be impractical if you need a limited run. - Limited Detail for Complex Designs: While screen printing excels at bold, graphic designs, it’s less effective for intricate details or fine lines. For photo-realistic images or designs with lots of gradients and color blends, screen printing can fall short, leading to distorted prints or additional costs to create more screens.
To overcome this, you can work with an experienced manufacturer and invest in simulated process screen printing, which is a specialized technique that can create photorealistic results on cotton garments. - Environmental Concerns
Traditional screen printing involves the use of chemicals for cleaning screens, which can result in more waste compared to sublimation.
While many print shops are moving to more eco-friendly practices, this is still a concern if sustainability is a key part of your brand’s ethos.
How Sublimation Works: A Digital Revolution in Printing
Sublimation printing is a relatively newer process that uses heat to transfer dye onto fabric. The design is first printed onto transfer paper using sublimation inks.
Then, the paper is placed on a polyester garment and heated to around 350°F to allow the ink to turn into gas and bond with the fabric fibers.
This process makes the print part of the fabric itself, resulting in vibrant and durable designs.
Pros of Sublimation Printing:
Sublimation printing delivers unique benefits that make it a standout choice for high-quality, all-over designs.
From vibrant color reproduction to unmatched durability, here’s why it’s gaining traction in the custom apparel world.
- Full-Color, Photorealistic Designs: Sublimation is ideal for intricate, colorful designs, especially when it comes to photo-realistic prints or full-coverage designs.
Unlike screen printing, there is no limit to the number of colors you can use, making it perfect for artwork with gradients or detailed images. Whether it’s a full-color portrait or a complex abstract pattern, sublimation can handle it with ease. - Soft, Breathable Prints: Because sublimation bonds the ink with the fabric, there’s no thick ink layer sitting on top of the garment.
This means the print feels soft to the touch, preserving the fabric’s natural breathability. This makes sublimation perfect for sportswear, performance gear, and casual wear, where comfort is key. - Durability: Sublimation prints are incredibly durable because the ink becomes part of the fabric. There’s no risk of cracking, peeling, or fading, even after extensive washes.
This makes sublimation the best choice for performance and athletic apparel that requires designs to hold up under heavy use. - Eco-Friendly Process: Sublimation printing is a relatively clean process that results in less waste than screen printing. Unlike screen printing, which requires chemicals and excess ink, sublimation only uses what’s necessary, making it a more eco-friendly choice.
Cons of Sublimation Printing:
While sublimation printing offers incredible advantages, it’s not without its limitations.
Here are some factors to consider before choosing sublimation for your next custom apparel project.
- Limited to Polyester Fabrics: Sublimation works best on polyester or polyester-coated fabrics. If your brand specializes in cotton or other natural fibers, sublimation is not a good option. However, if you’re willing to switch to polyester or poly-blend garments, sublimation can offer unmatched print quality and durability.
- No White Ink or Printing on Dark Fabrics: Sublimation cannot print white ink or lighten a dark fabric. This means you’re limited to light-colored or white garments. For designs that require white elements or for printing on dark garments, screen printing or other methods will be necessary.
- Requires Specialized Equipment: While sublimation can be cost-effective for small runs, it does require specialized equipment, including a sublimation printer and a heat press. This can represent a higher upfront investment compared to screen printing, especially if you’re producing large quantities (or DIYing instead of working with a manufacturing partner).
When to Choose Sublimation vs. Screen Printing
Deciding between sublimation and screen printing ultimately depends on your design needs, material choices, and production goals.
Here’s a breakdown of when each method excels:
Choose Sublimation If:
- You’re working with polyester or poly-blend fabrics and need full-color, intricate designs.
- Your brand focuses on sportswear, performance gear, or activewear, where comfort and breathability are essential.
- You want to create all-over prints or photo-realistic designs without worrying about color limitations.
Choose Screen Printing If:
- You’re printing on cotton or mixed fabric types.
- Your design is simple with bold colors or large blocks of text (Ex. logos, graphic tees, or streetwear).
- You need to create specialty effects (such as puff ink, glitter, metallics, or glow-in-the-dark) that sublimation can’t achieve.
- You’re doing large production runs and need a cost-effective option for bulk orders.
- Your brand requires long-lasting prints that hold up well on a variety of fabrics, especially when color opacity is important.
Choosing the Right Method for Your Brand
It all comes down to what your brand needs. Both screen printing and sublimation are top-tier processes in their own right.
Sublimation is unbeatable when it comes to full-color designs and durability, making it the ideal choice for sportswear, custom accessories, and performance apparel.
Screen printing, on the other hand, remains the gold standard for classic designs, specialty effects, and bulk production, especially for cotton-based apparel.
At Scrappy Apparel, we understand the importance of choosing the right printing method for your brand.
Whether you’re launching a new collection or scaling your operation, we’re here to guide you through the process and help you select the ideal printing technique for your designs.
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