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How Does Sublimation Work
The science behind permanent, vibrant full-color printing
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How Does Sublimation Work
Why It Makes the Difference
Your design doesn't go
on the fabric — it goes into it.
on the fabric — it goes into it.
Sublimation uses heat and pressure to transform ink into a gas that permanently bonds with the fabric fibers themselves. The result: vibrant, full-coverage color that will never crack, peel, or wash out — because it's part of the garment.
Step-by-Step Process
Step 1
Design Creation
Unlimited colors, gradients, and full-bleed coverage. No design restrictions — ever.
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Step 2
Transfer Print
Artwork is printed onto special transfer paper using sublimation inks.
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Step 3
Heat & Pressure
High heat converts ink to gas. It penetrates the polyester fibers under pressure.
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Step 4
Permanent Bond
As the fabric cools, ink solidifies inside the fibers. It's now part of the garment.
Why Sublimation Wins
Never Cracks or Peels
Unlike screen print or heat transfer — the ink is in the fiber, not on it.
Unlimited Design Freedom
Full-bleed coverage, gradients, photographic detail — all at no extra cost.
Lightweight & Breathable
No ink layers added to the surface — the garment performs exactly as designed.
Fade Resistant
Colors stay vibrant wash after wash — guaranteed for the life of the garment.
Perfect Reorder Matching
Digital files ensure exact color and design consistency every single time.
No Color or Setup Fees
12 colors or 1,200 — the price is the same. No screens, no plates, no limits.
Sublimation vs. Traditional Printing
| Feature | Sublimation | Screen Print | Heat Transfer |
|---|---|---|---|
| Feel on Fabric | ✔ Embedded — weightless | ✗ Sits on top | ✗ Sits on top |
| Crack / Peel | ✔ Never | ~ Over time | ✗ Common |
| Full-Bleed Coverage | ✔ Yes | ✗ No | ~ Limited |
| Color Limit | ✔ Unlimited | ✗ Typically 4–8 | ~ Limited |
| Breathability | ✔ Full | ~ Reduced | ✗ Reduced |
| Fade Resistance | ✔ Excellent | ~ Moderate | ~ Moderate |
| Reorder Consistency | ✔ Perfect match | ~ Batch variation | ~ Batch variation |
| Color / Setup Fees | ✔ None | ✗ Per color | ~ Per design |
Our Guarantee
Your design isn't applied to the fabric —
it becomes part of the fabric.
it becomes part of the fabric.
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Ordering Process
From artwork approval to delivery — step by step
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Ordering Process
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Factory Images & Process
See our production floor and quality control process
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Factory Images & Process
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Why Sublimation
Why sublimation outperforms screen printing and HTV
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Why Sublimation
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Tackle Twill
Our premium tackle twill options and when to use them
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Tackle Twill
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Common Questions
Answers to the most frequently asked questions
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Common Questions
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Lead Times
Standard, rush, and fill-in production timelines explained
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Lead Times
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Shipping & Returns
Delivery options, customs, and our satisfaction guarantee
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Shipping & Returns
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Fill-Ins
How to order additional pieces after your initial order
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Fill-Ins
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Designing My Garment
Design tools, file formats, and working with our art team
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Designing My Garment
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Care Instructions
How to wash, dry, and protect your sublimated garments
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Care Instructions
Sublimation Care Guide
Proper care keeps colors vivid for the life of the garment
Sublimated garments have dye bonded permanently into the polyester fibers — they're extremely durable when cared for correctly. Follow these guidelines and your garments will look great season after season.
Washing & Drying — Do This
✓ Do
Cold Water Only
30°C / 86°F maximum. Cold water protects dye bonds and prevents shrinkage.
✓ Do
Turn Inside Out
Before every wash. Protects the print surface from drum friction and abrasion.
✓ Do
Gentle Cycle
Low agitation prevents stress on seams and sublimated areas. Use mild detergent.
✓ Do
Tumble Dry Low
Low heat only, or air dry flat. Remove promptly — excess heat degrades sublimation inks.
✓ Do
Wash Separately
Keep away from towels, jeans, and rough fabrics that can abrade the print surface.
✓ Do
Mild Detergent
Sport-specific or gentle detergents only. Avoid brighteners and heavy enzymes.
Never Do This
✗ Never
No Bleach
Bleach chemically destroys sublimation dye permanently — even a small splash causes irreversible damage.
✗ Never
No Ironing the Print
Direct heat melts sublimation inks. If ironing is needed, turn inside out and use cool setting only.
✗ Never
No Fabric Softener
Coats polyester fibers with a waxy film that dulls sublimation colors over time.
✗ Never
No Hot Water / High Heat
Heat above 60°C can reactivate sublimation inks and cause color migration or bleeding.
✗ Never
No Dry Cleaning
Dry cleaning solvents break down sublimation inks and can permanently alter colors.
✗ Never
Don't Wring or Twist
Wringing stresses seams and distorts the garment structure. Gently press water out instead.
⚠ Protect Against Snags & Abrasion
The most common cause of garment damage — and entirely preventable
Real-World Damage Examples
Important: Velcro damage, pilling from improper washing, and abrasion from zippers or rough fabrics are not manufacturing defects and are not covered under warranty. These are entirely preventable with proper care.
Fasten all velcro before washing — both hook and loop sides, on every garment in the load. Even brief contact causes white fiber picks on colored fabric.
Zip all metal zippers fully closed before washing. Open zipper teeth act like a saw blade against the print surface inside the drum.
Remove all pins, badges, and number clips before washing. A single safety pin agitated through a wash cycle can create pull-holes in the fabric.
Use a mesh laundry bag for extra protection when washing with other items. Keeps garments isolated from velcro and hardware on other clothing.
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Sizing Questions
How to measure, fit guide, youth vs. adult, and more
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Sizing Questions
1 — How Do I Know What Size to Order?
Start by measuring each team member — don't guess by shirt size alone, as athletic cuts fit differently than everyday wear. You'll need three measurements:
- Chest: Measure around the fullest part of the chest, just under the armpits, keeping the tape parallel to the ground.
- Waist: Measure at the natural waistline (narrowest point of the torso).
- Hips: Measure around the fullest part of the hips.
Pro tip: For tops, chest is the primary measurement. For pants/shorts, use waist and hip. When between sizes, size up — athletic cuts are tailored close to the body.
2 — Can I Order Multiple Sizes?
Yes — mixed sizes in a single order are standard practice. Most team orders include a range of sizes within the same style. Here's how minimums work:
12 pcs
Minimum per style/design
1 pc
Minimum per size (fill-ins)
- There is no per-size minimum within an order — you can order 6 S and 6 XL if needed.
- The 12-piece minimum applies to the total order per style, not per size or per color.
- Need just one extra piece later? Fill-ins are available at 1 piece with a short lead time.
3 — Do Garments Run True to Size?
It depends on the cut. We offer three fit profiles — check the product card or ask your rep:
Athletic / Competition Cut
Fitted and close to the body. Designed for performance. Consider sizing up if between sizes or prefer a relaxed feel.
Relaxed / Standard Cut
True to size. Good for coaching staff, fan wear, or players who prefer more room. Follow the size chart directly.
Youth Cut
Runs smaller than adult equivalents. A YL (youth large) is roughly equivalent to an adult XS–S. Use the youth-specific size chart.
4 — Youth vs. Adult Sizing
Youth and adult sizes follow different scales. Here's a general crossover reference — always use actual measurements for the best fit:
| Youth Size | Chest (in) | Waist (in) | Closest Adult |
|---|---|---|---|
| YXS | 24–26 | 22–23 | — |
| YS | 26–28 | 23–25 | — |
| YM | 28–30 | 25–26 | Adult XS |
| YL | 30–32 | 26–28 | Adult XS–S |
| YXL | 32–34 | 28–30 | Adult S |
Note: Youth garments use shorter body lengths and narrower shoulders. Older/taller youth athletes may prefer an adult XS or S over a YXL for better shoulder and torso coverage.
5 — Women's vs. Men's Cuts
Most REVO styles are available in both Men's and Women's cuts. The differences are intentional and consistent across the product line:
Men's Cut
- Straight torso profile
- Wider shoulder seam
- Longer body length
- Available XS–3XL
Women's Cut
- Tapered at the waist
- Narrower shoulder seam
- Shorter body length
- Available XS–2XL
Women athletes who prefer more coverage or a looser fit may opt for the Men's cut in a smaller size — this is common. Ask your rep if you're unsure which to spec for a co-ed team.
6 — What If a Size Doesn't Fit?
Sublimated garments are custom-made to order, so we encourage measuring carefully before submitting your roster. That said, we have two options if something doesn't fit:
Fill-In Order (Recommended)
Order the correct size as a single-piece fill-in. Minimum is 1 pc. Turnaround is typically 2–3 weeks. This is the most common solution and produces a perfectly matched garment.
Size Exchange
If the size issue is caught quickly and your order is still in production, contact your rep immediately — we may be able to adjust. Post-production exchanges are evaluated case by case.
Best practice: Request a pre-production size sample from your rep before placing large team orders. This eliminates sizing surprises entirely.