When it’s time to place a bulk apparel order for your business, whether for uniforms, giveaways, staff events, or brand promotions, you’re likely weighing two popular methods: screen printing and sublimation, both have their place in the apparel world, but they deliver very different results, especially when it comes to quality, design capabilities, and long-term value.
This article breaks down the pros and cons of each method, with a specific focus on what matters most for bulk business orders. If you’re thinking about ordering bulk sublimated shirts for businesses or comparing options for your next merch run, this guide will help you make the right call.
Understanding the Basics
Screen printing is the traditional method most people are familiar with. Ink is pushed through a stencil (screen) and applied onto the fabric, one color at a time. It’s reliable, widely available, and cost-effective for simple designs.
Sublimation, on the other hand, is a more modern process that uses heat and pressure to bond ink directly into the fibers of the fabric. This is often referred to as a full sublimation printing service, and it’s beneficial for complex, full-color designs or all-over prints.
Design Flexibility
Sublimation wins, hands down, when it comes to design freedom. It allows for full-color, edge-to-edge designs, gradients, detailed patterns, and even photorealistic graphics. Because the ink becomes part of the fabric, there’s no cracking, peeling, or heavy ink feel.
Screen printing is more limited. Each color in the design requires a separate screen, which increases costs and complexity. It works best for solid colors and simple logos, not full-cover prints.
So if your brand identity is bold, colorful, or detail-heavy, a full sublimation printing service gives you much more creative freedom and consistency across every shirt.
Durability Over Time
When you’re ordering in bulk, durability matters. You want every shirt to hold up after dozens of washes without fading, cracking, or peeling.
Sublimated prints don’t sit on top of the fabric; they’re infused into it. That means the design won’t wash out or deteriorate over time. These shirts stay vibrant and sharp for the long haul.
Screen printing, while durable with proper care, is more prone to wear. Over time, especially with frequent washing, screen-printed graphics can crack or fade, especially on lower-quality garments or high-contact areas like the chest or back.
If you’re ordering bulk shirts for active staff, outdoor teams, or long-term use, sublimation is the more reliable choice.
Comfort and Feel
One of the hidden advantages of sublimation is comfort. Since the ink becomes part of the fabric, the shirt remains soft and breathable. There’s no added weight or stiffness from thick ink layers.
In contrast, screen-printed shirts can feel heavier in the printed areas, especially with large graphics or multiple layers of ink. This can make the garment less comfortable, particularly in warm environments or during physical activity.
If your staff is wearing these shirts all day, or you’re creating promotional gear that needs to feel good right out of the bag, full sublimation printing service delivers a lighter, smoother wearing experience.
Cost Considerations
Screen printing is often cheaper for large runs with simple designs. If you’re printing one or two solid colors on hundreds of shirts, it’s usually the more affordable option. That’s why it’s still popular for basic corporate tees or one-off event shirts.
bulk sublimated shirts for businesses However, sublimation can become cost-effective when you factor in the long-term value. Because there’s no limit on color or placement, you’re not paying extra for complexity. And with bulk sublimated shirts for businesses, you save money on reorders, since you won’t need to replace worn-out or faded shirts as frequently.
Fabric Limitations
Screen printingworks on a wide range of fabrics, including cotton, cotton blends, and synthetics. It’s flexible if your brand prefers a natural fabric, such as 100% cotton.
Sublimation requires polyester or polyester-blend garments. The sublimation process only bonds properly with synthetic fibers, so fabric selection is more limited.
So, screen printing offers more fabric flexibility. Sublimation works best with performance-style poly fabrics.
So, Which Should You Choose?
It comes down to priorities.
If you need a simple logo on a basic tee, and price is your biggest concern, screen printing works well.
But if you’re after bold branding, full-color flexibility, long-term durability, and a more premium experience, sublimated shirts are a smarter investment.
