Challenges in Printing: The Complexity of Polyester

Customizing shirts through printing techniques such as screen printing and direct-to-garment printing has been a common practice in various industries, from promotional events to sports apparel. However, a series of challenges arise when it comes to printing on shirts, especially those made with a high percentage of polyester.

Sublimation: The Greatest Challenge

Both in screen printing and direct printing, the biggest challenge faced is dye migration This phenomenon consists of stains on the prints, usually in the color of the shirt itself. For example, when printing on a black shirt, it's possible and likely that the final print will have grayish stains, compromising the quality of the end result.

Screen printing:

Screen printing, a traditional printing technique, faces significant challenges when dealing with polyester fabrics. Polyester has a smooth and non-porous surface, making it difficult for screen printing ink to adhere. Furthermore, the fabric's elasticity at high temperatures can cause distortions in the printed image, resulting in inaccurate or blurred details.

Direct to Garment:

Direct to garment printing, on the other hand, offers an alternative solution, but it also faces its own challenges. This technique allows printing directly onto the fabric, bypassing the need for a screen. However, the ink used in direct printing often does not adhere well to polyester fibers, resulting in faded colors, broken images, and inferior print quality.

Polyester Fabrics:

The popularity of polyester fabrics in T-shirts adds an additional layer of complexity. Polyester is known for being shrink-resistant and quick-drying, making it a preferred choice for many consumers. However, its synthetic composition presents unique challenges when it comes to printing, as the ink often struggles to effectively penetrate the fabric fibers.

Solutions and Innovations:

Despite the challenges faced in printing on polyester shirts, the industry is constantly seeking solutions and innovations. New ink formulations are being developed to improve adhesion and durability of printing on synthetic fabrics. Furthermore, advances in printing technology are allowing for greater precision and quality, even on challenging fabrics.


Printing on jerseys, especially those made with a high percentage of polyester, presents unique challenges that require creative and innovative solutions. While screen printing and direct-to-garment printing remain popular methods, it is crucial for industry professionals to be aware of the specific challenges associated with printing on synthetic fabrics. With a continued focus on research and development, it is possible to overcome these challenges and deliver high-quality printing results, even on polyester jerseys.

estampagem têxtil


Leave a Reply

Your email address will not be published. Required fields are marked *

This site uses Akismet to reduce spam. Learn how your comment data is processed.

Garment Decoration

We are available to help you create your clothing brand or personalized merchandise with your own logos.

We work for companies and private individuals with no production minimums.

Recent Posts
Follow us