How Sublimated Jerseys Are Made

Ever wondered how sublimated jerseys are made? Unlike a basic printed shirt with graphics stuck on top, a sublimated jersey has its colors and artwork baked permanently into the fabric. The result is an edge-to-edge, full-color kit that won't crack, peel, or fade. Here's a clear look at the cut-and-sew, made-to-order process behind every jersey we build.

From Your Design to Print-Ready Art

It all starts with your artwork. Using our free online designer, you add your team name, numbers, logos, and exact colors, then our team preps a print-ready file. Because every kit is fully custom, there's no minimum order quantity and no design limits. Want a bold edge-to-edge pattern, fade, or pro-style trim? It's all possible when the art is printed into the fabric instead of layered on top.

Once your design is approved, it's laid out across large sheets to match each panel of the garment, so the graphics line up perfectly once the pieces are sewn together.

The Sublimation Process, Step by Step

Dye sublimation uses heat to turn solid dye into gas, which then bonds directly with the fibers of the fabric. Here's how it comes together:

• Printing: Your design is printed in reverse onto transfer paper using specialized sublimation inks.
• Heat pressing: The paper is placed against white polyester fabric and run through a heat press. Under high heat and pressure, the ink turns to gas and dyes the fibers from the inside.
• Bonding: As the fabric cools, the color is locked in permanently. There's no surface coating to wear off, which is why sublimated kits stay vibrant wash after wash.

Because the dye becomes part of the fabric, your jersey stays soft and breathable with no heavy, plasticky print weighing it down. Want the deeper science? Read what a sublimated jersey is and see how sublimation compares to screen printing.

Cut, Sew, and Quality Check

This is the cut-and-sew part. The printed fabric is cut into panels, then expertly stitched together into a finished garment. This made-to-order approach means seams, collars, and sleeves are tailored to the style you chose, not just printed onto a blank shirt. Every piece gets a quality check before it ships in the US.

The same process powers full team kit across every sport, from custom soccer jerseys and basketball jerseys to baseball and beyond. Whatever your team plays, the build is consistent: vibrant, durable, and made just for you.

Ready to design yours? Explore our custom jerseys or dive into the full guide to sublimation to learn more about the technology behind your kit.