Sublimated Volleyball Jerseys vs Screen Printed Jerseys

How Each Method Works

Dye-sublimation uses heat and pressure to convert solid dye into a gas that penetrates and bonds with polyester fibers. The result is color that is literally inside the fabric — it cannot sit on top of fibers because it IS the fiber at the molecular level. This process produces vibrant, permanent color with unlimited design possibilities.

Screen printing applies ink to the surface of the fabric through a stencil (screen). Each color requires a separate screen, and the ink sits on top of the fabric rather than bonding with it. This is a proven, cost-effective method with specific advantages for certain order types.

Design Flexibility

This is where sublimation has a clear advantage. Because sublimation uses no screens and the number of colors does not affect cost, designs can incorporate unlimited colors, gradients, photographic imagery, and edge-to-edge patterns without any design constraints or per-color pricing. Our sublimated volleyball jerseys regularly feature complex artwork that would be impossible or prohibitively expensive with screen printing.

Screen printing works best with 1–4 solid colors. Each additional color adds cost and complexity. Gradients and photographic images are not feasible with traditional screen printing. For simple designs — a team name, number, and one or two solid accent colors — screen printing performs well.

Durability and Longevity

Sublimation wins decisively on durability. Because the color is bonded into the fabric fibers, it cannot crack, peel, fade, or wash out. A well-made sublimated jersey can last 5+ years of regular use and washing without any noticeable color degradation. Teams often wear sublimated jerseys for multiple seasons without replacement due to visual wear.

Screen-printed inks sit on top of the fabric and are subject to cracking over time, particularly in areas that flex repeatedly during play — sleeves, underarms, and number areas. Higher-quality screen printing inks (plastisol, discharge) are more durable than cheaper alternatives, but no screen-printed jersey matches the longevity of sublimation.

Cost Comparison

For simple, one or two-color designs on a stock jersey, screen printing can be more cost-effective per unit than sublimation, especially for large quantities. This makes it attractive for practice jerseys where design complexity is not important.

For multi-color or fully custom designs, sublimation is almost always the more economical choice. Screen printing charges by the color — a six-color design can cost twice as much per unit as a two-color design. Sublimation pricing is essentially flat regardless of how many colors or how complex the artwork.

Which Should You Choose?

Choose sublimation when: you want full-color, edge-to-edge custom designs; you need the design to last multiple seasons; your jersey uses player names and numbers (sublimated names and numbers never peel); or your team color scheme requires gradients or complex patterns.

Consider screen printing when: you need very simple designs quickly and cost is the primary concern; you have cotton or cotton-blend jerseys; or you are producing practice jerseys where longevity is less critical than price.

For competitive game-day uniforms at any level, we recommend sublimation. For most custom volleyball jersey orders, the design quality, durability, and long-term value of sublimation justify the investment.