Sublimation vs. Tackle Twill, Which Custom Jersey Method Is Right for Your Team?
A side-by-side comparison of full color sublimation and tackle twill for custom team jerseys. Cost, durability, design freedom, and lead time.
When you order custom team jerseys, decoration method is one of the biggest decisions you'll make. The two dominant options in the USA are full color sublimation and tackle twill.
Here's how they actually compare.
Sublimation
Sublimation prints the design directly into polyester fibers using heat. The result is a jersey where the artwork is part of the fabric.
Pros
- Unlimited colors, gradients, and complex patterns
- No raised edges, nothing to peel or crack
- lightweight (decoration adds zero weight)
- Best for modern, dynamic team designs
Cons
- Only works on light color polyester (dark fabrics need digital methods)
- Less of a "premium heritage" feel
- Can look flat compared to stitched twill on traditional designs
Best for: football, basketball, baseball alternates, soccer, lacrosse, hockey practice gear
Tackle Twill
Tackle twill is layered fabric letters and numbers stitched onto the jersey body. It's the method MLB and many heritage college programs use.
Pros
- Premium feel, you can run your hand over the letters
- Multi-decade lifespan with proper care
- Classic, timeless look
- Highly durable through laundry cycles
Cons
- Higher cost per jersey
- Fewer color options (usually 2–3 layers max)
- Adds weight to the jersey
- Longer production lead times
Best for: baseball home/away jerseys, varsity football, alumni and heritage teams
Hybrid: sublimated body + tackle twill names/numbers
The best of both worlds. The body of the jersey is fully dyed (gradients, patterns, panels), and the names + numbers are stitched on tackle twill.
This is what most varsity football and college baseball programs choose, and it's what Midfield offers as a default on premium kits.
Cost comparison (per jersey, USA)
| Method | Typical price |
|---|---|
| Full color sublimation | $55–$95 |
| Tackle twill on stock blank | $65–$110 |
| Sublimated body + tackle twill | $85–$140 |
What we recommend
- Football: sublimated body + tackle twill numbers
- Baseball: full tackle twill (heritage), or sublimated alternates
- Basketball: full sublimation
- Practice gear: full sublimation
Build it your way
Start with the Team Builder and pick your decoration method, or browse Team Store for ready to customize jerseys with official quantity pricing.