Screen Printing Sublimation Printing Embroidery & DTF
Not sure which printing method is right for your brand? Wearlets uses all four — and this page explains exactly how each one works, when to use it, and what to avoid. No jargon. Just clear answers so you can order with confidence.
custom clothing printing and embroidery
Screen Printing, Sublimation, Embroidery
— Which One Does Your Brand Need?
The printing method you choose affects how your garment looks, how long it lasts, what fabric it goes on, and what it costs. Getting this right saves you money and gives your customers a product they keep coming back to.
custom clothing printing and embroidery At Wearlets, we offer four decoration methods: screen printing, sublimation printing, embroidery, and DTF (Direct to Film) printing. Each one has a specific strength. None of them is the “best” option in every situation — the right choice depends on your garment type, your design, your order quantity, and what kind of look you’re going for.
On this page, we explain each method in plain language — what it is, how it works, what it looks great on, and where it falls short. By the time you finish reading, you’ll know exactly which method to ask for. And if you’re still unsure, our team will advise you for free when you send us your enquiry.
Screen Printing
Bold, Vibrant, Cost-Effective
Screen printing is the oldest and most widely used method in the custom clothing industry — and for good reason. A separate screen (stencil) is created for each colour in your design, and ink is pushed through that screen onto the fabric. The result is bold, opaque colour with a slightly raised, tactile feel.
Screen printing works on almost any fabric — t-shirts, hoodies, sweatshirts, tote bags, and more. It is especially effective on cotton and cotton-blend garments where the ink sits cleanly on the surface without bleeding into the fibres.
How Screen Printing Works — Step by Step
- A separate screen is made for each colour in your design — a one-colour logo needs one screen, a four-colour design needs four.
- Ink is pushed through the screen onto the fabric surface using a squeegee blade, one colour at a time.
- Each layer is cured (heat-dried) between colours to prevent bleeding and ensure the ink bonds firmly to the fabric.
- The finished print sits on top of the fabric as a solid, vibrant layer — softer water-based inks or bolder plastisol inks depending on your needs.
Your design has many gradient colours or photographic detail (use sublimation or DTF instead), or if your garment is a stretch fabric like polyester-spandex (the print can crack under repeated stretching).
Sublimation Printing
All-Over, Full Colour, Fade-Proof
Sublimation printing is in a different league when it comes to full-colour, all-over designs. Instead of applying ink to the surface of the fabric, sublimation uses heat and pressure to turn special dye into a gas that bonds permanently into the polyester fibres. The result? Colour that is literally part of the fabric — it cannot crack, peel, or fade.
This is the method we use for our custom tracksuits, sports jerseys, NFL uniforms, and performance activewear. The design covers the entire garment from collar to cuff with no borders, no white edges, and no limitation on how many colours or gradients your artwork contains.
How Sublimation Printing Works — Step by Step
- Your artwork is printed onto special transfer paper using sublimation inks — it looks dull at this stage, not vibrant yet.
- The paper is placed against the fabric and both are fed through a heat press at around 200°C under firm pressure.
- The heat turns the sublimation ink into a gas that opens the polyester fibres and bonds the dye permanently inside them.
- When cooled, the fibres close around the dye — the colour is now locked inside the fabric, with no surface layer to crack or peel.
Your garment is 100% cotton — sublimation does not work on cotton because the dye needs polyester fibres to bond to. For cotton garments with full-colour designs, use DTF printing instead. Sublimation also only works clearly on white or very light-coloured base fabrics.
Embroidery
Premium, Textured, Incredibly Durable
Embroidery is the most premium-feeling decoration method available. Thread — not ink — is stitched directly into the fabric by an automated embroidery machine, producing a raised, textured finish that looks and feels expensive. It is the decoration method most associated with quality, heritage, and professionalism.
Embroidery is the go-to method for chest logos on polo shirts, brand badges on varsity jackets, coaching staff names, and headwear branding. Unlike printed decoration, embroidery never fades, never peels, and does not crack — it will outlast the garment itself.
How Embroidery Works — Step by Step
- Your design is converted into a stitch file (DST format) by our digitisation team — this maps every thread path and stitch type for the machine.
- The garment is placed in an embroidery hoop on the automated machine, which holds it flat and taut for accurate stitching.
- The machine stitches the design directly into the fabric, thread colour by thread colour, building up the design layer by layer.
- A backing material is trimmed away and the garment is inspected — leaving a clean, raised logo that is part of the fabric structure.
Your design contains fine gradients, photo-realistic detail, or very thin lines — thread cannot replicate these with the same accuracy as ink. Embroidery is also heavier than printing, so it is not recommended on lightweight, stretch performance fabrics where added stiffness would affect movement.
DTF Printing
Full Colour on Any Fabric, Any Quantity
DTF — Direct to Film — is the newest and fastest-growing decoration method in custom apparel. It combines the colour range of sublimation with the fabric flexibility of screen printing. A design is printed onto a special transfer film, which is then heat-pressed onto any garment. It works on cotton, polyester, blends, and even nylon — making it the most versatile option available.
DTF is perfect when you need detailed, full-colour designs on cotton garments, or when your order is too small to set up screen printing screens, but you still want crisp, photographic-quality artwork on your clothing. No colour limits, no fabric restrictions, and no minimum colour count.
How DTF Printing Works — Step by Step
- Your artwork is printed onto a clear PET film using a DTF printer loaded with CMYK and white inks — full colour in a single pass.
- A hot-melt powder adhesive is applied to the wet ink on the film, then the film is cured in an oven so the powder bonds to the print.
- The cured film is heat-pressed onto the garment — the adhesive melts and bonds the print to the fabric, on any fabric type.
- The film peels away cleanly leaving a soft, flexible, full-colour print that stretches with the garment and washes well.
You need an all-over, edge-to-edge design covering the entire garment — for that, sublimation is still the better choice. For very large print areas at high volume, screen printing typically has a lower unit cost than DTF.
Screen Printing vs Sublimation vs
Embroidery vs DTF — Full Comparison
One table to help you make the right decision for your garment and design. When in doubt, ask us — we’ll recommend the best method for free.
| Feature | 🖨️ Screen Printing | 🌈 Sublimation | 🧵 Embroidery | 🎨 DTF |
|---|---|---|---|---|
| Works on cotton | ✓ Yes | ✗ No | ✓ Yes | ✓ Yes |
| Works on polyester | ~ Limited | ✓ Best choice | ✓ Yes | ✓ Yes |
| All-over / edge-to-edge | ✗ No | ✓ Yes — full garment | ✗ Logo placement only | ~ Large placement possible |
| Unlimited colours | ~ 1–6 typically | ✓ Unlimited | ~ 12+ thread colours | ✓ Unlimited |
| Photo / gradient detail | ✗ Limited | ✓ Photographic quality | ✗ Not suitable | ✓ Photographic quality |
| Works on dark garments | ✓ With underbase | ✗ Light fabrics only | ✓ Yes | ✓ Yes |
| Durability / wash life | Good (can crack with age) | ✓ Permanent — never fades | ✓ Lifetime durability | Good (100+ washes) |
| Premium feel / texture | Flat to slightly raised | Smooth, part of fabric | ✓ Raised, luxury texture | Soft, smooth surface |
| Best order size | 30+ pcs ✓ | 30+ pcs ✓ | 30+ pcs ✓ | 30+ pcs ✓ |
How to Order Custom Printed or
Embroidered Clothing From Wearlets
Simple. Five steps from your design file to your finished garments landing at your door.
Share your artwork (AI, EPS, PNG, or sketch) and tell us which garment and printing method you’re interested in.
We position your design onto a digital garment mockup and send it back within 48 hours for your approval — free, no commitment.
A real, printed or embroidered sample garment is made and shipped to you. Check the colour, finish, and placement before bulk.
Once you approve the sample, your full order is produced with triple inline quality checks — typically 3 to 5 weeks.
Finished garments are packed and shipped directly to your US, UK, or EU address via DHL or FedEx with full tracking.
Manufacturing or print defects replaced or refunded within 30 days of delivery.
DHL / FedEx direct to USA, UK & EU with full door-to-door tracking.
A printed/embroidered sample is always approved by you before bulk production starts.
Quote-based on method, garment, and quantity. Free quote within 24–48 hours.
FAQ — Screen Printing, Sublimation,
Embroidery & DTF
Clear answers to the questions we hear most. More on our full FAQ page →
Have a Design?
Tell Us Which
Method You Need.
Free mockup and quote within 24–48 hours. We’ll recommend the right printing method for your garment and design — and show you exactly how it will look before you commit to a single piece.
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