“Sublimation” is a fancy word for a printing process that turns solid inks into gas, which then bonds to the fabric of your shirt. If that sounds complicated, that’s because it is. But the end result is a beautiful full-color print that will last for ages.

Sublimation isn’t as easy as 1-2-3. It’s a complex process that requires specialized equipment and training. Many custom apparel companies will use sublimation on wholesale blanks, but this is not the ideal way to produce sublimated garments.

Instead, we like to use a cut and sew process that ensures each print is flawless and that the garment is of higher quality.

Let’s talk about what these processes entail so you can fully understand the benefits of cut and sew sublimation.

What is Sublimation T-Shirt Printing?

Sublimation is a printing process that uses heat-activated dyes to print designs onto fabric. It’s an excellent way to produce full-color, full-coverage prints on apparel.

The sublimation process begins with a white or light-colored garment. Your manufacturer will take your design and apply the ink to the fabric. The ink turns into a gas when it’s heated, which allows it to penetrate the fibers of the fabric. As the ink cools, it solidifies and becomes embedded within the fabric.

This printing method differs from traditional screen printing, where the ink sits on top of the fabric instead of becoming part of it. As a result, the design can crack, fade, or peel over time. Sublimation printing ensures that your design will be long-lasting.

sublimation printingBenefits of All Over Sublimation Printing

So, what’s so special about sublimation anyway? Well, this printing process has unique benefits that make it an attractive option for many custom apparel projects.

Here are a few of the reasons why you may want to choose sublimation printing for your project:

Sublimation Can Produce Full Color, High-Resolution Prints

While screen printing is best for designs with only a few colors, you can print as many colors as you want with sublimation. If you want your design to really pop, sublimation is a phenomenal printing method to choose. The quality is excellent, and you can print photorealistic images onto your garments.

Sublimation is Ideal for Full Coverage Prints

Another advantage of sublimation is that it can be used to print all over a garment. With traditional printing methods, it’s difficult to print over seams and hems. But with sublimation, the ink penetrates the fabric’s fibers, so you can print over any area of the garment.

Sublimation Stands the Test of Time

It scores 10/10 for durability. Your finished garment will look vibrant for years to come.

Limitations of Sublimation Printing

While sublimation printing offers a lot of benefits, there are also a few drawbacks that you should be aware of before you choose this printing method.

Here are a few of the potential limitations of sublimation printing:

It Can Only Be Used on Certain Fabrics

Sublimation works best on polyester. The process does not work well on cotton, so sublimation is not the right option if you definitely want to print on a cotton garment.

The Process Doesn’t Work Well on Dark-Colored Garments

Sublimation also doesn’t work well on dark-colored garments. The prints tend to be less vibrant on dark fabrics because the ink doesn’t show up as well. Screen printing would be a better option if you need to print on a dark garment.

You Need to Work With an Expert Manufacturer

It’s crucial to work with a manufacturer that has experience with sublimation. Otherwise, you may not be satisfied with the final product.

If you’re considering sublimation printing for your next project, keep these benefits and limitations in mind. This printing method will produce stellar prints when executed correctly.

(If you have questions about what will work best for your project, you are welcome to speak with our team!)

Why the Cut and Sew Process Works Well With Sublimation

The cut and sew process is exactly what it sounds like. It’s a manufacturing method where the fabric is dyed and then cut and sewn into the final garment.

The cut and sew process is often used for garments that are too complex to be dyed in one piece. It’s also a good choice for garments that need to be printed all over, such as t-shirts.

The cut and sew process has a few advantages that make it a great option for sublimation printing.

Your Garment Will Look Perfect

Cut and sew sublimation allows for a much more precise print, as there is no risk of the design being distorted when the garment is assembled.

Without the cut and sew process, sublimation can result in a blurry or inconsistent print. This is because the design is printed on the garment after it has been assembled, which can cause the fabric to stretch and distort the print.

Especially if you DIY your custom apparel or work with a partner that isn’t as experienced with sublimation, you may also notice white creases or inconsistent patches on the finished garment after sublimating it. The cut and sew process helps to avoid these issues, as the fabric is cut before it is sewn into the garment. This ensures that your print will be flawless, regardless of the size or shape of the garment.

The Garment Will Be of Higher Quality

The cut and sew process also results in a higher quality garment overall. This is because the garment is made from start to finish with care and attention to detail.

Here are a few ways the cut and sew process improves garment quality:


When you order a custom garment that has been cut and sewn, you can be sure that it was made with care and that it will last for many years to come. Each seam is sewn with precision, and the fabric is cut specifically for your garment. This results in a much higher quality garment than one that was simply printed on a blank.


The cut and sew process results in a more polished look. This is because each garment is made to your specifications, and there is less risk of inconsistencies in the print or fabric.


Another advantage of the cut and sew process is that it allows you to create a completely unique garment. Instead of choosing from a limited selection of pre-made garments, you can work with a manufacturer to create a one-of-a-kind piece that will be the star of the show.

What Does Cut and Sew Sublimation Mean For Your Brand?

Your product is the core of your business. By investing in the cut and sew process, you’re investing in your brand’s future.

If you’re serious about making your apparel brand a household name, it’s time to consider cut and sew sublimation printing. It can help you create high-quality, unique garments that will make your brand stand out from the competition.

Here’s why you should say YES to cut and sew sublimation for your next custom apparel project:

You Can Charge More for Cut and Sew Garments

Because the cut and sew process results in a higher quality garment, you can charge more for your products. Your customers will be happy to pay a little extra for a garment that is well-made and looks great.

Charging more for your apparel now will help you reinvest in your business and create even better products down the line.

You’ll Have More Satisfied Customers

The apparel industry is competitive, so it’s crucial to prioritize customer satisfaction. Cut and sew sublimation will help you do just that.

Your customers will be impressed with your garments’ quality and the high detail level in your designs. As a result, they’ll be more likely to purchase from you again in the future and recommend your brand to their friends.

Your Brand Will Be More Unique

With the cut and sew process, you can create truly unique garments that no one else will have. This helps you stand out from the competition and build a strong brand identity.

For example, you could customize your garment with:

  • Varying panel sizes and shapes
  • Unique sleeve styles
  • Pockets, zippers, or other embellishments

The most famous brands in the world are known for their unique style, and you can achieve the same level of success by incorporating the cut and sew process into your sublimation apparel.

You Can Create a Cohesive Brand Image

If you want to create a cohesive brand image, the cut and sew process is essential. By working with a professional manufacturer, you can ensure that your garments are all of the same high quality and match your brand’s aesthetic.

This is important because it helps you develop an identity for your brand. When customers see your products, they should be able to recognize them as yours instantly.

You’ll Have More Control Over Your Products

When you work with a manufacturer on a cut and sew sublimation project, you’ll have more control over the final product. This means you can ensure that your garments are exactly what you want them to be, and you won’t have to settle for less.


Our Sublimation Experts at Scrappy Apparel Are Ready to Help!

Scrappy Apparel offers a comprehensive custom apparel manufacturing solution. We source top-of-the-line fabrics, inks, and other materials to produce luxury-level garments for our customers.

We have a team of highly skilled sublimation experts who can bring your vision to life, and we have relationships with some of the best sewing contractors in the world.

When you invest in cut and sew apparel, you want to make sure you have the right manufacturing partner to bring your vision to life. With Scrappy Apparel, you can rest assured that your garments will meet all your expectations.

Our team consists of professionals who genuinely care about your brand and the quality of your garments. We’ve been in the apparel business for over 16 years. We know what it takes to produce garments that will help you build your brand.

We know your to-do list is a mile long, so we’ll handle every step of the manufacturing process for you. All you need to do is send us your design, and we’ll take it from there!

Our Brand Building Process (BBP) is designed to take the pressure off you, but still involve you in all the important decision-making processes. For example, you’ll get to review detailed pre-production layouts before your order goes into production.

This way, you can be sure that your garments will be exactly as you imagined them. If you’re not happy with something, we’ll make changes until you are. After you give us the green light to begin production, we’ll manufacture your order and ship it to your doorstep for free!

Check Out Our Work!

View our portfolio to see some of our previous work and get inspired for your own project!

We’ve worked with some of the biggest brands in the world, and we’re confident that we can help you take yours to infinity and beyond.

Want to feel the quality of our garments yourself? Order samples to experience the Scrappy Apparel difference. We think you’ll be sold as soon as your fingers graze the fabric.

What to Expect When You Work With Scrappy Apparel

  • A streamlined manufacturing process
  • Retail-soft garments that exceed your standards
  • Competitive rates with price breaks for higher quantity orders
  • An experienced and knowledgeable team
  • A hassle-free experience from start to finish!
  • Free shipping to the USA

You can expect nothing less than the best when you partner with Scrappy Apparel. Get a free estimate for our cut and sew sublimation services:

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