PentathlonWhen a club orders new kit, one of the first real decisions is how the colours, crest, names and numbers actually go onto the jersey. The two main methods are full-dye sublimation and tackle twill, and the right one depends on your sport, your budget and the look you want. Here is a plain-English guide to the difference, so your committee can choose with confidence.
What is full-dye sublimation?
Sublimation prints your design into the fabric rather than onto it. The colour and graphics are turned into a gas under heat and bonded into the fibres, so they become part of the jersey. Because the dye is in the fabric, there is nothing sitting on top to crack, peel or fade, even after a full season of hard use and heavy washing.
The big advantage is design freedom. Sublimation has no limit on the number of colours, so you can have gradients, patterns, sponsor logos, player names and numbers all printed in one process at no extra cost per colour. It also adds no weight to the jersey, which keeps match kit light and breathable in warm weather.
What is tackle twill?
Tackle twill is the traditional, stitched method. Numbers, letters and badges are cut from pieces of twill fabric and sewn onto the jersey. It gives a raised, premium, classic look that many clubs associate with heritage kit, and it is extremely hard-wearing.
The trade-offs are cost and weight. Twill is more labour-intensive because every number and letter is cut and stitched by hand, so the price rises with each piece of lettering, and the finished jersey is heavier than a sublimated one. It also suits simpler, bold designs more than complex multi-colour graphics.
Sublimation vs tackle twill at a glance
- Design freedom: Sublimation wins. Unlimited colours, gradients and all-over patterns. Twill suits clean, classic marks.
- Durability: Both last well. Sublimation cannot peel because it is dyed in; twill is heavy-duty stitched fabric built to survive contact.
- Cost: Sublimation is usually more cost-effective, especially with lots of colours or personalisation. Twill costs more as you add lettering.
- Weight: Sublimation is lighter, which matters for match jerseys in the heat. Twill adds weight.
- Look and feel: Sublimation is smooth and modern. Twill is raised, textured and traditional.
The hybrid option
You do not always have to choose. A hybrid kit uses sublimation for the body of the jersey, giving you full colour and design, with tackle-twill numbers and lettering stitched on top for that premium, classic finish. It is popular with clubs that want a bold identity but still want the heritage look of stitched numbers.
Which should your club choose?
As a rough guide: if your design is colourful, has sponsors, or you want lightweight match jerseys, sublimation is usually the better and more affordable choice. If your club has a simple, iconic look and you value the traditional stitched feel, tackle twill is worth the extra. If you want both, go hybrid.
Sport matters too. For fast, warm-weather codes like soccer and Gaelic football and hurling, lightweight sublimation is the popular pick. For contact codes like rugby and American football, both work, and twill or hybrid numbers stand up well. For baseball, stitched twill lettering is a classic look many teams still prefer.
How we do it
Pentathlon makes kit both ways. We produce full-dye sublimation, traditional tackle twill and hybrid kit in our own workshop, so we can recommend the right method for your design and budget rather than pushing one process. Because you order factory-direct, there is no reseller margin on top, and you deal with the people actually making the kit. See how factory-direct works, or request a quote and we will send a mock-up in your colours.