Coach guide
Sublimated vs screen printed vs tackle twill jerseys: which is best for your team?
Short answer
For travel softball and baseball, sublimation is usually the best choice: unlimited colors and patterns, names and numbers included, light and breathable, and it never cracks or peels. Screen printing suits simple, low-cost practice wear. Tackle twill gives a traditional stitched look but is heavier and costs more per letter.
The three decoration methods explained
Sublimation
The design is printed onto transfer paper with special dye inks, then pressed onto white polyester fabric under heat. The dye turns into a gas and bonds with the fibers, so the fabric itself becomes the color. Panels are then cut and sewn into the jersey. Because the whole garment is printed, there is no limit on colors, gradients or patterns.
Screen printing
Ink is pushed through a mesh screen onto the fabric, one screen per color. It's cost-effective for simple designs in large runs, but every extra color adds setup, and names and numbers usually need a separate process.
Tackle twill
Letters and numbers are cut from twill fabric and stitched onto the jersey. It's the traditional "pro" look with texture and depth, but it adds weight and stiffness and is priced per letter.
Side-by-side comparison
| Sublimation | Screen print | Tackle twill | |
|---|---|---|---|
| Colors and patterns | Unlimited, same price | Each color adds cost | Limited by layers |
| Names and numbers | Included | Usually extra | Extra, per letter |
| Feel and weight | Light, breathable | Ink layer on top | Heavy, stiff areas |
| Cracking/peeling | Doesn't crack or peel | Can crack over time | Edges can lift |
| Fabric | Polyester only | Cotton or poly | Most fabrics |
| Single-jersey reorder | Easy, same file | Setup per run | Possible, costly |
| Best for | Travel teams, bold designs | Simple practice tees | Traditional HS/adult look |
When to choose each method
- Choose sublimation if you want team-specific designs, play in heat, need names and numbers, or expect to add players during the season.
- Choose screen printing for one- or two-color practice shirts or fan tees in big quantities.
- Choose tackle twill if a traditional stitched look matters more than weight and cost.
Some teams combine methods, for example a sublimated jersey with a small stitched patch logo. Send us your idea and we'll advise.
Caring for sublimated uniforms
- Wash inside-out in cold water with similar colors
- No bleach or fabric softener
- Tumble dry low or hang dry; never iron directly on the print
- Pre-treat grass and clay stains before washing