Manufacturing & Embellishment Processes

At Serious Sport, we offer a wide range of garment manufacturing and embellishment services across teamwear, trainingwear, leisurewear and fully bespoke match kit. From embroidered club crests through to fully sublimated playing kits, every product is produced using processes selected to best suit the garment, fabric and intended use.

This page explains the different decoration and manufacturing methods we use, why garments can vary in appearance between products and batches, and how we continue to develop our products and production processes over time.

Choosing the Right Decoration Method

Different garments and products require different decoration methods depending on the fabric, intended use, durability requirements and visual appearance.

For example:
• Embroidery is often preferred for premium leisurewear and outerwear
• DTF printing is ideal for lightweight performance garments and detailed sponsor logos
• Sublimation is best suited to fully bespoke performance teamwear

Our team will always recommend the most suitable application method based on the garment type, logo detail, garment construction and intended use.

Embroidery

Embroidery is one of the most traditional and premium methods of garment decoration and is commonly used for Club badges, School logos and Initials.

Embroidery works by stitching thread directly into the garment using digitised embroidery files and commercial embroidery machines.

Benefits of Embroidery
• Premium textured finish
• Highly durable
• Long lasting through repeated washing
• Professional appearance
• Ideal for polos, hoodies, jackets, caps and leisurewear

As embroidery is stitched directly into the fabric, the appearance can vary slightly depending on:
• Fabric thickness
• Garment stretch
• Material composition
• Stitch density
• Garment colour and texture

Certain lightweight performance garments may not be suitable for large embroidered logos due to the nature of the fabric. For some products such as caps and bobble hats, we may also recommend simplified logo versions to ensure the best possible embroidery finish due to the limitations and complexity of stitching onto smaller or textured areas.

DTF Printing (Direct to Film)

DTF printing is a modern heat-applied print process used widely across sportswear and teamwear. The design is printed onto a specialist film before being heat-pressed onto the garment surface.

Benefits of DTF Printing
• Sharp detail and vibrant colours
• Suitable for small or intricate logos
• Lightweight finish
• Excellent for initials, squad numbers and sponsor logos
• Suitable for a wide variety of garments and fabrics

DTF printing allows for excellent flexibility across mixed garment types and smaller order quantities.

As with all heat applied applications, final appearance can vary depending on:
• Fabric texture
• Garment composition
• Heat tolerance of materials
• Garment colour
• Placement and sizing

Sublimation Printing

Sublimation is the primary process used across our bespoke match kit and fully custom garments.
Unlike embroidery or heat applied printing, sublimation dyes the design directly into the fibres of the fabric during manufacturing using heat and pressure. This means the design becomes part of the garment itself rather than sitting on top of the fabric.

Benefits of Sublimation
• Customisable design options
• Flexibility on colours, patterns or gradients
• No cracking or peeling
• Ideal for performance sport
• Fully bespoke appearance

At Serious Sport, we work from our own bespoke sublimation colour chart using RGB colour references to help achieve the closest possible colour consistency across custom garments and designs. We also have a range of custom designs available to edit via our 3D Kit builder. Custom designs are available on request, design setup fees may apply.

Because sublimation is dyed into the fabric itself, colour appearance can vary depending on:
• Fabric type
• Fabric weave
• Material composition
• Surface texture
• Garment cut and panel construction

Performance sports fabrics are also designed with varying levels of stretch, compression and fit depending on the sport, garment style and intended use. As a result, sizing and fit may differ between product types, garment styles and manufacturers.

Dip-Dyed Fabrics vs Sublimated Garments

One of the most common questions within teamwear production is the difference between dip-dyed fabrics and sublimated garments.

Dip-Dyed Fabrics
Dyed fabrics are fabrics that are dyed to a single colour before the garment is manufactured. Once the fabric has been dyed, the garments are then cut and sewn before logos are added through embroidery or print.

This is traditionally the process used for:
• Stock trainingwear
• Hoodies
• Tracksuits
• Polo shirts
• Outerwear
• Leisurewear

Benefits
• Consistent core garment colours
• Ideal for stock ranges
• Efficient for repeat production

Sublimated Garments
Sublimated garments are manufactured using white fabric before colours and designs are heat transferred directly into the garment panels.

Benefits
• Full customisation
• Bespoke colours
• Complex designs
• Unlimited sponsor integration
• Unique club identity

Colour Variations & Shade Tolerances

Within garment manufacturing and sportswear production, slight colour variation is common and considered standard across the industry.

All garments can vary in appearance between:
• Fabric types
• Garment styles
• Production batches
• Decoration methods
• Manufacturers and brands

For example:
• A polyester performance shirt may display colour differently to a cotton hoodie
• Embroidered thread colours may appear slightly different to printed colours
• Matte fabrics may appear darker than gloss fabrics
• Heavyweight fabrics can absorb dye differently to lightweight performance fabrics

Even within the same brand or product family, there can be acceptable commercial shade tolerances between batches due to:
• Dye batch variations
• Raw material sourcing
• Fabric mill tolerances
• Seasonal production runs
• Manufacturing locations
• Production processes

These tolerances are commercially accepted throughout the garment and sportswear industry.
Digital visuals, website imagery and on-screen colours are also representative only and may vary between screens, devices, fabrics and final production methods.

Sampling & Artwork Approval

Where possible, Serious Sport can provide:
• Digital visuals
• Embroidery samples
• Print strike offs
• On fabric examples

This allows customers to review appearance, dimensions and positioning ahead of production where required.

Customers are responsible for checking and approving:
• Spelling
• Sizing
• Colours
• Logo positioning
• Sponsor details
• Personalisation

Once approved, production will proceed based on the confirmed artwork and specifications.

Garment Care & Maintenance

To maximise garment lifespan and decoration quality, please refer to individual care instructions on items.
For the majority of items we recommend:
• Washing garments inside out
• Washing at low temperatures
• Avoiding tumble drying where possible
• Avoiding ironing directly onto prints or embellishments
• Fastening Velcro items separately from performance garments
• Avoiding harsh abrasion against printed or knitted surfaces

Improper washing, abrasion or repeated contact with rough surfaces may impact garment appearance over time.

Please note that some performance fabrics, particularly lightweight polyester sports fabrics, can be susceptible to pilling or bobbling over time through abrasion and repeated friction during use. This is common across the sportswear industry and can be caused by contact with rough surfaces or materials such as Velcro fastenings found on cricket gloves, wicket keeping equipment, pads, bags and certain sports accessories. Similar wear can also occur on garments such as netball dresses when applying netball patches through repeated friction during play or contact with abrasive surfaces.

Where possible, garment specific wash care guidance and instructions are also included on individual product pages.

Sustainability & Continuous Improvement

At Serious Sport, we are continually reviewing and improving our garments, fabrics, embellishment methods and manufacturing processes to provide the best possible products and service for our customers.

We also continue to explore more sustainable fabrics, manufacturing methods and packaging solutions where possible as part of our ongoing product development.

As part of this ongoing development:
• Garment specifications may change over time
• Fabrics may be updated or improved
• Decoration methods may evolve
• Manufacturing locations and processes may vary
• Product construction and fit may be refined

Whilst we always aim to maintain consistency where possible, improvements and developments within the sportswear industry mean that products and processes may vary over time.

This commitment to continuous improvement allows us to:
• Improve garment performance
• Enhance durability and comfort
• Increase sustainability
• Improve print and embroidery quality
• Reduce lead times
• Expand customisation capabilities

Serious Sport Commitment

At Serious Sport, we pride ourselves on combining modern manufacturing techniques with practical teamwear expertise.

Whether producing embroidered leisurewear, printed training garments or fully bespoke sublimated match kit, our focus remains the same:
• Quality
• Performance
• Durability
• Service
• Transparency
• Continuous improvement

If you have any questions regarding garment manufacturing, embellishment methods, garment care or colour matching, our team is always happy to help advise on the most suitable solution for your club, school or organisation. Please contact sales@serioussport.co.uk / 01256 398633.