1. What is Ink Dye Sublimation?

Ink dye sublimation is a process by which ink is applied to special (typically 72" x 56") paper by one of two processes: "Digital", or "Screen" (see below). Once the image has been printed onto it the paper is laid onto the bed of a gigantic heat press, the fabric is laid onto it, and when top of the press comes down, the two are super heated under pressure. At a certain temp the solid ink changes to a gas without ever becoming a liquid (hence "sublimation"), and bonds with the fabric on the molecular level. This results in a precisely rendered and vibrantly colored jersey, yet the fabric's performance is never affected.

2. What is Digital Sublimation?

For orders under 200 we use the "digital" process because a separate file is created for each. This paper is inked using a special digital printer and incredibly expensive high tech sublimation inks. This process enables us to produce individual shirts, or, within the context of a team order, we can change names, logos, and even colors within the basic design. Frequently, we produce a shirt body design for a team, wherein each team member will have their name and their individual sponsor logos on their respective jerseys. This individual's file is then saved, and extra identical shirts can be recreated at any time for no extra art charges (digital re-print), or, if for example his sponsors change, we can print new shirts with different logos for only the nominal price of removing and replacing art (see art price list. These shirts are more expensive than Production process shirts because this printing process itself is slow, and the materials (i.e. papers and inks) are far more costly expensive.

3. What is Production Sublimation?

For orders of over 200 or more shirts we use the Mechanical Screen Production process. This method employs the use of high tech screens to apply the inks. There is one screen for each color used on the shirt. This process is much faster then digital and much more cost effective for large orders, but personalization of individual jerseys can only be done on a completed garment by embroidery. An example of the production concept goes like this: A manufacturer orders a production run of 200 shirts and asks us to design them in such a way as to have open areas (absence of color) at the top of the shirt where we can, after these shirts are fully produced, further customize the open for their "Competition Team" by adding the team members individual's names and other smaller sponsor logos.

4. Semi-Custom

This is where you choose a shirt body design layout from one of our existing templates. You will find them in our Semi-Custom Gallery.

5. Graphic Artists.

"Lining Up" the shirt, or Matching, Colors vs Fabrics
Important notes about the services of an outside graphic artist (even one we recommend): These folks are graphic artists, not shirt specialists makers, so your "Full Custom" fantastical design must still be vetted by us to make sure that two things are right correct:
A. The shirt has to "Line Up" correctly. Explanation: The shirt sleeves, front, and back of a shirt, are asymmetrical, but the artists never draw them that way, therefore, with shirt designs in which there are lines, or a pattern, that flows around a sleeve, or from the chest, through the sleeve, and into the back, frequently must be corrected by us (design rate of $55 per hour) so that the integrity of the design is maintained when the shirt is sewn together.
B. Colors: We need to vet the colors to be sure that they will turn out to be what you want. Remember, our Techstatic fabric is a silvery grey, but a graphic artist has no choice but to treat it as though it were white. If the exact colors are critical, this would involve our time at $55 per hour.