The evolution of printing and embellishment techniques: From ancient stitches to POD
This is the evolution of printing techniques – a journey from hand-stitched embroidery and block prints to sublimation, DTG, and DTF.
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Sublimation vs screen printing are both popular apparel printing techniques. Sublimation dyes the design into synthetic fabrics, resulting in smooth, vibrant prints. Meanwhile, screen printing layers ink on top of the material for bold, textured graphics.
So which one should you use to print your products? In this guide, we’ll break down the pros, cons, and key differences between sublimation vs screen printing to help you choose the best fit.
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Key takeaways
- Sublimation is a digital printing method that uses heat to transfer dye into synthetic materials. It’s ideal for full-color, high-detail designs.
- Screen printing is a traditional method that pushes ink through stencils onto a surface. It’s best for bold, simple graphics with solid colors.
- Compared to screen printing, sublimation delivers more vibrant colors, smoother gradients, and long-lasting prints – but only works on synthetic, light-colored fabrics.
- Screen printing offers more material flexibility and supports specialty inks, but it’s only cost-effective for bulk orders.
What is sublimation printing?
Sublimation is a digital printing method that uses heat to transfer dye directly into a product. The result is a smooth, long-lasting print that feels like part of the material – not something sitting on top.
The sublimation printing process involves several steps:
- A designer prepares a digital image using raster image processing software to ensure proper color and sizing.
- The image is printed onto specialized transfer paper using sublimation ink cartridges.
- The transfer paper is placed on the product, typically made from polyester fabrics or a polymer-coated surface.
- A heat press applies high temperature and pressure, turning the dye sublimation ink into gas.
- The gas bonds with the fabric fibers or coating, embedding the design into the material as it cools.
Compared to screen printing, sublimation delivers more vibrant colors and detailed printing results. However, it’s limited to light-colored synthetic materials only.
What is screen printing?
The traditional screen printing technique uses stencils and ink to apply designs onto a surface. The ink sits on top of the printed material, creating interesting textures and bold visual effects.
How the screen printing process works:
- A designer creates the artwork and prepares a separate screen for each color in the design.
- Each screen is turned into a detailed screen print stencil that blocks out areas where ink shouldn’t go.
- The stencils are mounted onto a screen printing press.
- A squeegee applies plastisol ink across the screen, pressing the ink through open areas onto the material.
- Each color is printed one at a time, with drying in between layers.
- Once all the colors are applied, the product goes through heat curing to set the ink.
Screen printing is one of the most popular shirt printing methods for bulk orders, with lower per-unit costs at higher volumes. It’s more cost-effective than other dye transfer techniques and works on a wide range of materials.
However, since setup is more complex, many print-on-demand (POD) companies require minimum order quantities or don’t offer it for individual orders.
Tip
See the full comparison between direct-to-garment (DTG) vs screen printing.
The difference between screen printing and sublimation
Both sublimation printing vs screen printing offer exceptional print quality. However, these popular printing methods differ in several ways – from the materials they work with to the types of designs each method handles best.
Material compatibility
Sublimation printing works exclusively on synthetic fabrics because the dye can only bond with plastic-based fibers.
Best materials for sublimation printing:
- 100% polyester or polyester blends. Natural materials like cotton don’t have the right chemistry for sublimation, so the ink won’t absorb properly or stay in place.
- Polymer-coated blank items with a special surface that absorbs sublimation ink and locks in the design.
Silk screen printing is more flexible as it doesn’t need to bond with the fabric – it simply prints designs on top of the surface. That makes it compatible with both natural and synthetic materials.
Best materials for screen printing:
- Cotton or cotton blends. The surface holds plastisol ink well and produces bold, durable prints.
- Paper-based and flat surfaces. These materials allow the ink to rest cleanly on the surface.
Print quality and detail
Sublimation printing offers sharper detail and smoother gradients than screen printing.
Since this digital printing method embeds dye directly into the material – rather than layering ink on top – it handles fine lines and complex artwork easily.
However, sublimation works best on light-colored fabrics. On dark materials, designs can appear dull or even disappear due to the lack of a white base.
Meanwhile, screen printing uses stencils and a separate screen for each color. Because each layer must align perfectly, it’s harder to achieve ultra-fine detail or reproduce photo-quality images.
Still, it has its strengths – screen printing uses opaque inks, making it ideal for bold designs.
Creative possibilities
Sublimation printing is best for:
- All-over print (AOP) clothing designs.
- Digital photos or illustrations with color gradients.
This is possible because sublimation doesn’t use physical screens. The design is printed digitally on specialized sublimation paper, then transferred to the product using a heat press. That allows for virtually unlimited color combinations.
On the other hand, screen printing is perfect for:
- Logos or minimalist graphics with limited color palettes.
- Effects that require specialty inks, like metallics, puff ink, glow-in-the-dark, or glitter.
Screen printing is complex to set up because aligning all the color layers takes precision. But once it’s ready, the process becomes efficient – making it one of the most popular printing techniques for large orders.
Tip
Check our design guide and discover everything you need to create flawless prints.
Products you can print on
The sublimation printing process is ideal for products that need a smooth finish, bright colors, and high durability. Here are some examples:
- AOP apparel, like jerseys and leggings for fitness brands.
- Custom drinkware, such as mugs and tumblers.
- Accessories like mouse pads and phone cases.
Screen printing works on a wider range of materials and supports specialty inks for premium results. That makes it ideal for:
- Merch t-shirts, hoodies, and tote bags for events or brands.
- Posters, flyers, and retail packaging for promotional campaigns.
- Workwear where bold logos and a professional finish matter.
Durability and feel
Sublimation-printed graphics are embedded into the material itself, resulting in a fantastic print quality that’s highly resistant to fading, cracking, or peeling. It’s ideal for products that go through regular washing or heavy daily use.
- Care tips: Wash in cold or lukewarm water. Air dry to preserve the vibrant colors and prevent fading over time. Don’t scrub printed surfaces with abrasive materials.
Screen-printed designs sit on top of the fabric. While still long-lasting, they can be more prone to fading or cracking – especially if exposed to friction, heat, or repeated washing.
- Care tips: Turn garments inside out before washing. For hard-surface products, wipe gently with a damp cloth – avoid soaking or harsh chemicals that can lift the ink.
Cost
The price difference between screen printing and sublimation comes down to the equipment and prep involved for each job.
In sublimation printing, the basic setup includes:
- A sublimation printer with ink cartridges
- Specialized transfer paper
- A heat press
- Sublimation blanks
Because the sublimation printing process doesn’t involve physical screens or stencils, there’s less prep involved. Just upload your design, print it onto the sublimation paper, and transfer it to the product.
Screen printing involves more equipment and time upfront, especially if a design uses multiple colors. A typical setup includes:
- A screen printing press
- Plastisol ink
- A separate screen for each color
- Squeegees, cleaning stations, and curing equipment
Every time you create a new design, you need to make a new stencil and prepare a new screen. This means extra time, materials, and labor before printing even starts.
For reference, Custom Ink – which uses screen printing for 90% of its products – charges around $28 per shirt for a minimum order of six t-shirts – $168 in total. That higher per-unit cost for small orders reflects the extra setup required to start the print job.
On the other hand, the cheapest unisex AOP cut-and-sew t-shirt in Printify’s Catalog costs $23.12 per unit. This price covers all the production costs needed to print just one item – no minimums required.
Production volume
Sublimation is perfect for small-batch or one-off production, thanks to its minimal setup and fast turnaround. It’s ideal for:
- Made-to-order products
- Personalized gifts
- Testing products
In contrast, screen printing becomes more efficient at scale. Once the screens are set up, the cost per unit drops significantly – making it a top choice for:
- Bulk orders of custom merchandise
- Team or company swag
- Wholesale production
Environmental impact
Sublimation is considered more environmentally friendly because it produces minimal waste and uses water-based sublimation ink. There’s no need for water in the cleanup process or chemical-heavy materials.
Screen printing typically involves more waste. The process uses cleaning agents, disposable stencils, and excess ink. For businesses focused on sustainability, sublimation offers a cleaner solution.
Tip
Looking to reduce your brand’s environmental impact? Check out our guide to eco-friendly Print on Demand.
Sublimation vs screen printing: An overview
Need a quick comparison between sublimation printing vs screen printing? Check out the table below:
| Sublimation | Screen printing | |
|---|---|---|
| Works on | Polyester and coated items. | Cotton, paper, and blended fabrics. |
| Print quality and detail | Sharp detail and smooth gradients. | Bold, solid colors. Less suited for fine detail. |
| Creative possibilities | Full-color designs on light-colored fabrics. | Simple designs with few colors. Allows special effects. |
| Product types | AOP apparel, mugs, phone cases, home decor. | T-shirts, tote bags, posters, paper-based goods. |
| Durability and feel | Smooth, soft, hard to crack or peel. | Slight texture, may crack or fade over time. |
| Cost | Low setup costs. | High setup costs – cheaper with large orders. |
| Production volume | Individual or large orders. | Ideal for bulk orders. |
| Environmental impact | Minimal waste, no harsh chemicals. | More waste and cleanup. Uses more chemicals and materials. |
Pros and cons of screen print vs sublimation
Use this side-by-side breakdown to see which printing method best suits your needs.
Sublimation printing
| Pros | Cons |
|---|---|
| Full-color prints with smooth gradients | Only works on polyester or coated products |
| Great for detailed designs and digital photos | Doesn’t work on dark fabrics |
| Low setup costs for small orders | Final colors depend on the base material – harder to color-match |
| Long-lasting prints that won’t crack or fade | Not ideal for textures or raised effects |
Screen printing
| Pros | Cons |
|---|---|
| Works on cotton fabrics, paper, plastic, and more | Not ideal for detailed or photo-based designs |
| Best for simple, bold graphics and large text | Can fade or crack over time without proper care |
| Cost-effective for bulk production | High setup time and cost for small batches |
| Good for special effects like metallic or neon inks | Uses chemicals and creates more waste |
How to choose between sublimation vs screen printing
Choose sublimation printing if you want:
- Vivid results with high detail, smooth gradients, and full-color artwork.
- All-over prints that hold up over time without fading or cracking.
- Small-batch or one-off products made from polyester or coated materials.
Choose screen printing if you want:
- Bold, graphic-heavy designs like logos, large text, and solid shapes on cotton, paper, or plastic.
- Cost efficiency for bulk orders and scalable production.
- Flexibility with materials and finishes, including dark fabrics and metallic, puff, or neon inks.
Focus on your POD store while Printify handles the rest
You don’t have to master every printing method to build a successful print-on-demand business. With Printify, you can focus on your designs and leave the production to us.
1. Sign up and choose your products
Create your free Printify account – no upfront costs required. Then, browse our Catalog and find everything from sublimation shirts and mugs to cotton t-shirts and tote bags.
2. Customize your products
In the Product Creator, you can upload photos or artwork you’ve made with graphic design software like Adobe Photoshop. Alternatively, create something from scratch using our built-in graphics library and AI image generator.
3. Order or sell your products
Publish your products to your store – Printify integrates with platforms like Shopify, Etsy, and Amazon. Whenever there’s an order, our global network of Print Providershandles the printing and shipping to your customers. Bulk orders are also available.
FAQ
Sublimation printing typically lasts longer than screen printing because the ink adheres to the fabric fibers, making it resistant to cracking, peeling, or fading.
In contrast, screen printing ink sits on top of the material, which can wear down with frequent washing or heavy use.
Sublimation and screen printing are two different printing methods. Sublimation uses heat to transfer dye into the material itself. Screen printing uses stencils to print ink that sits on top of the surface, layer by layer.
The key disadvantages of sublimation printing are its limited material compatibility and inability to print on dark fabrics. It only works on polyester or polymer-coated surfaces, and because it doesn’t use white ink, designs won’t show up properly on dark backgrounds.
Whether sublimation or screen printing is better depends on what you’re printing and your business needs.
Sublimation is better for full-color, detailed designs on light-colored polyester or coated items. It’s ideal for vibrant, long-lasting prints and small-batch orders.
Screen printing is ideal for creating bold graphics on a wide range of materials in large quantities. It supports specialty inks and effects, but takes more setup than other printing methods.
Conclusion
Here’s a quick recap of sublimation vs screen printing to help you decide:
- Choose sublimation for full-color designs on light-colored polyester products with no minimum orders.
- Choose screen printing for bold graphics on cotton or other natural or blended materials and for placing bulk orders.
Printify makes it easy to bring your ideas to life with the most popular printing methods. With 1,300 products, easy design tools, and a global network of trusted Print Providers, you can focus on growing your store while we handle the rest.
