For a jersey that is worn and washed every week, the most durable technique is sublimation: under heat, the ink turns into a gas and enters the polyester fibre instead of sitting on top of it. So there is no layer that can crack and no film that can peel off. The one condition: a polyester fabric.
By the Flare Custom team · Updated 16 October 2026
Sublimation. Of the four common techniques — sublimation, heat-transfer vinyl (flock), screen printing and digital transfer — it is the only one where the colour becomes part of the fabric. With the other three, the print is a layer added on top of the jersey: it ages separately, with washing and friction. At Flare Custom, everything is made in full sublimation in our workshop in Bulgaria (EU): the design, logos, sponsors, names and numbers.
Seen in cross-section, the difference is obvious. With sublimation, the fibres themselves take on the colour. With a surface print, a rigid layer sits on a fabric that stretches, folds and gets washed: that is where cracks and peeling start.
The design is prepared in CMYK or Pantone references, never in RGB. You receive a proof: nothing is printed until you approve it.
The artwork is printed with sublimation inks on transfer paper, at the real size of each panel of the garment.
Paper and fabric go under a heat press. The ink turns from solid to gas and penetrates deep into the polyester fibre.
As it cools, the ink is locked into the fibre. The printed fabric is then cut and sewn in our workshop in Bulgaria, with a check before dispatch.
A crack is a rigid layer that breaks when the fabric stretches. Flaking is a film whose adhesive gives way under heat, friction and washing. With sublimation there is neither a layer nor glue: the ink is in the fibre.
Nothing sits on the fabric: nothing can crack when it stretches or folds.
No heat-applied film: nothing can peel off in the wash or through friction.
The fabric stays soft, light and breathable, even under a large logo or number.
Names, numbers and sponsors wear at the pace of the jersey, never before it.
Durable does not mean indestructible: the fabric itself wears with friction and snags, and washing too hot or tumble drying tires the fibres. Hence the importance of care, see below.
No technique is perfect. Here is what you should know before ordering, exactly as stated in our terms of sale.
Sublimation only works on polyester fibres, not on cotton. All our fabrics are polyester, or polyester and elastane for close-fitting pieces.
We print on white fabric: ink cannot lighten a fabric, and the white in the design is fabric left without ink. A black jersey is therefore a white jersey printed all over. Very fine white lines can appear in folds: this is normal with sublimation.
A screen displays in RGB (light), printing is done in CMYK (inks). Very saturated screen colours — electric blues and greens, very bright reds — come out duller. Fluorescent colours are only possible with a Pantone fluo reference written on the quote.
Our terms (article 2.4) allow ±10% on colour compared with the digital proof, ±5 mm on placement and ±3% on dimensions. To judge the real result before the run, you can ask for a test piece.
Every piece is made to order: 2 to 4 weeks of production after proof approval, plus shipping. An express option is possible, from 72 hours to 2 weeks depending on the product and quantity, on request; the surcharge is shown on the quote.
Full details are in our terms and conditions of sale, article 2.4.
A comparison of the processes themselves, criterion by criterion, without targeting any manufacturer. Here, vinyl means cut-film lettering (flex or flock); transfer means digital printing on a film applied with heat.
Swipe the table to see the other techniques →
| Criterion | Sublimation | Vinyl (flex) | Screen printing | Transfer |
|---|---|---|---|---|
| Where the ink is | Inside the fibre | Cut film, heat-glued on the surface | Ink layer deposited on the surface | Printed film, heat-glued on the surface |
| Wash resistance | Excellent: nothing to peel | Can peel or crack over time | Good, but can crack and fade | Varies with the film; can crack |
| Colours | Unlimited, gradients and photos | One colour per film | One colour per screen; gradients difficult | Many colours, gradients possible |
| Printable area | The whole garment, edge to edge | Limited areas: names, numbers, logos | Limited areas | Limited areas |
| Feel and breathability | Unchanged | Added thickness; less breathable area | Noticeable layer; less breathable area | Noticeable film; less breathable area |
| Compatible fabrics | Polyester, white base | Almost all, cotton and dark included | Almost all, cotton and dark included | Almost all, cotton and dark included |
| Cost in small quantities | Same price whatever the number of colours; from 1 piece with us | Economical for a few simple names and numbers | Expensive for small runs: one screen per colour | Suited to small runs; cost depends on artwork size |
| Ideal for | Club jerseys, full kits, rich designs | Adding a name to an existing garment | Large runs of cotton T-shirts, few colours | Small runs on cotton or dark garments |
General comparison of the processes. Real results also depend on the quality of the materials and the application.
Sublimation, without hesitation: wash resistance, unlimited colours, names and numbers built in. It is the only technique we use.
On cotton, with one or two colours and a large volume, screen printing remains relevant. We do not offer it: our garments are sublimated polyester.
Rather than adding vinyl to a stock jersey, we remake the same sublimated piece from 1 piece, identical: same design, same colours, with their name and number.
Since the colours are in the fibre, repeated washing does not harm them. It is the technical fibres that need looking after: a few simple habits are enough.
All our advice: caring for sublimated kit.
Full sublimation, made in Bulgaria (EU), from 1 piece. You approve a proof before production.