The custom T-shirt market grows fast. Clients want bold designs, soft prints, and fast delivery. Your printing method affects quality, cost, and profit. The key debate is screen printing vs sublimation. Both work. Both have strengths. But they fit different needs.
What Is Screen Printing?
Screen printing uses a mesh to push ink onto fabric. Each color needs its own screen. Setup takes time. Once ready, production moves fast.
Why shops choose screen printing:
- Best for large bulk orders
- Creates bold, vibrant colors
- Works on cotton, polyester, and blends
- Requires skilled operators and prep
Suppliers use it to produce uniforms, events, and high-volume runs.
What Is Sublimation Printing?
Sublimation uses heat to transfer dye onto fibers. The print becomes smooth, not layered.
Why shops choose sublimation:
- Perfect for polyester fabrics
- Supports full-color, photo-quality prints
- Great for all-over or complex designs
- Fast setup and easy changes
Sublimation is popular for sportswear, fashion pieces, and customized gifts.
Fabric Thickness: Screen Printing vs Sublimation
Fabric weight affects print quality and feel.
| Fabric Thickness (gsm) | Screen Printing | Sublimation |
|---|---|---|
| 120–160 gsm (light) | Bold colors but may feel heavy | Smooth, integrated print |
| 160–200 gsm (medium) | Best durability and cost | Crisp detail on polyester |
| 200–280 gsm (heavy) | Long-lasting and strong | Limited, polyester only |
Tip: Sublimation works only on polyester. Screen printing works on most fabrics.
Advantages of Each Method
Screen Printing Benefits
- Low cost per unit for large runs
- Durable and long-lasting prints
- Works on many fabric types
- Bold, solid colors
Sublimation Benefits
- Smooth, soft-feel finish
- Unlimited colors and gradients
- Ideal for polyester sportswear
- Fast setup, easy to switch designs
Daily Maintenance Tips
Proper maintenance keeps machines productive.
Screen Printing Care
- Clean screens after every run
- Keep inks sealed and fresh
- Maintain mesh tension
- Replace squeegees when worn
Sublimation Care
- Wipe heat press surfaces daily
- Use correct sublimation paper and inks
- Calibrate temperature for consistent results
- Store polyester blanks in dry conditions
Cost and Profit Considerations
- Screen printing: Higher setup, lower unit cost. Profitable for 100+ shirts.
- Sublimation: Low setup, higher unit cost. Best for polyester, small runs, and custom orders.
Choice depends on fabric type, order numbers, and client needs.
How to Decide
- Use screen printing for cotton, uniforms, and large bulk orders.
- Use sublimation for polyester, full-color artwork, and all-over designs.
- Many shops use both. Screen printing covers cotton and bulk jobs. Sublimation expands your services to polyester and premium designs.
Conclusion
The choice between screen printing vs sublimation is about fit, not better or worse.
- Screen printing wins in bulk durability.
- Sublimation wins in detail, comfort, and full-color prints.
For B2B buyers, investing in both methods helps serve more clients, reduce risk, and grow faster in the custom apparel market.
