Printing, Sublimation, & Embroidery
We offer a wide range of printing techniques to make your brand stand out. Our clients and well-known brands prefer these methods, which we’ve detailed below.
1. Screen Printing
Screen printing is a cost-effective method of creating high-quality artwork on garments. It works by using screens as stencils, applying layers of ink onto the print surface.
This technique is especially popular for bulk orders because it ensures vibrant results and durable prints that can last a long time, even after multiple washes.
Normally, screen printing can become expensive for designs with more than 4 colors, as each color requires its own screen.
However, at Gears Sphere, we minimize these costs by managing the entire process in-house. We handle everything from tracing to the preparatory work, eliminating the need for middlemen and their extra costs.
2. Puff Printing
Puff printing is a unique printing technique that uses special puff ink. When exposed to heat, the ink expands to create a 3D effect on fabric. This method is popular with clothing brands that want to add a bubbly look to their designs, making it perfect for bold logos and eye-catching patterns.
It works especially well on heavy GSM fabrics like hoodies, sweatshirts, joggers, zippers, and other high-quality apparel, where the raised texture enhances the overall appeal of the garment.
The process includes designing, digitizing, selecting high-quality puff ink, and preparing screens with an emulsion.
Once the printing press is set up, the ink is applied and cured to achieve a dimensional effect. It adds a tactile, textured finish that helps to elevate a brand’s uniqueness.
3. Heat Transfer Printing
Heat Transfer Printing uses plastisol inks that are printed onto transfer paper or vinyl and then applied to a garment using heat and pressure.
The process leaves a thin layer on the fabric, which can be easily felt by hand. This technique is suitable for both natural fabrics and synthetic fabrics, making it ideal for sportswear fabrics or photographic prints with more than 4 colors.
While it is a cost-effective method, the layered texture and limited durability make it less appealing for those seeking long-lasting, premium-quality prints.
Many brands and especially our clients prefer more durable options like screen printing for premium results.
4. Digital Printing
Digital printing is a modern printing technique that uses advanced digital technology to transfer designs directly onto fabric.
Unlike traditional methods, digital print doesn’t require screens or plates, making it ideal for small batches, custom designs, or intricate patterns.
This method ensures high color accuracy, vibrant results, and a smooth finish, making it a popular choice for clothing brands looking to achieve photorealistic designs on their apparel.
The process begins by preparing the design in a digital format, ensuring every detail is clear and scalable.
The design is then printed directly onto the fabric using specialized inkjet printers that use pigment-based or water-based inks. This allows for seamless reproduction of multi-color designs and gradients, perfect for t-shirts, hoodies, and high GSM fabrics. Digital print is especially suitable for customized designs and on-demand printing, offering exceptional flexibility for personalized branding.
5. DTF Printing
DTF printing (Direct-to-Film printing) is a popular printing method where designs are printed directly onto a special film and then transferred onto fabric using heat and pressure.
This method is known for its high-quality results and versatility, offering vibrant, full-color prints on a wide range of materials.
It is especially effective for intricate designs, gradients, and detailed artwork.
DTF printing works well on cotton, polyester, blends, and synthetic fabrics. It is suitable for custom apparel. This technique allows for a durable, long-lasting finish and can handle both light and dark fabrics.
Due to its ability to print vibrant colors, complex designs, and gradients, DTF printing is also good.
6. Dye Sublimation
Dye sublimation is a specialized printing process where dye pigments are first printed onto a transfer medium and then applied to fabric or garments using a combination of heat and pressure.
This method allows the inks to penetrate deeply, creating a permanent, full-color image that feels smooth with no hand feel.
It’s a popular choice for achieving high-quality, photographic print results that are resistant to scratching or cracking, ensuring long-lasting designs.
This technique is particularly suitable for the sportswear category, as it works best with polyester fabrics. Whether you need bold artworks or vibrant designs, dye sublimation guarantees full-color accuracy and a flawless finish.
At our facility, it serves as the default printing method for polyester garments, offering unmatched durability and design quality.
7. Embroidery
Embroidery is an art where thread or yarn is used to stitch intricate patterns onto fabrics, giving garments a classy appearance. It’s known for being long-lasting and durable, which makes it a great choice for garments that need a premium look.
We offer multiple types of embroidery using polyester threads on both natural fabrics and synthetic fabrics. For smaller designs, typically below 5 cm, embroidery may not be the best choice, as it may not create a clean result.
Embroidery works well on both heavy fabrics and light fabrics and is ideal for those who want a sturdy, upscale design. However, it’s not always suitable for complex designs or large artwork where a tonal or gradient color effect is needed, as this is more difficult to achieve.
Additionally, embroidery tends to cost more than a standard screen print, but it provides a unique, high-quality finish that makes it worth the investment.
- Machine Embroidery
- 3D (Puff) Embroidery
- Chenille Embroidery
- Embroidery patches
8. Reflective Printing
Reflective screen printing uses reflective ink to create luminous designs on fabric, combining aesthetics with functionality.
The process starts with preparing the artwork and coating the screen with emulsion.
Next, the reflective ink mixed with glass beads or microspheres is applied to the fabric through a stencil. After printing, the design is cured with heat, ensuring it bonds to the fabric.
Reflective screen printing improves visibility for outdoor activities like running or cycling, adds an eye-catching element to garments, and offers durability, resisting fading and cracking.
It works best on fabrics like cotton, polyester, and blends, offering versatility for a range of apparel, including t-shirts, hoodies, jackets, and safety vests.
It is the most premium and expensive printing method due to the specialized materials and processes involved, but Gears Sphere provides this service to clients who wish to incorporate it into their apparel.
5. Rhinestone Printing
Rhinestone printing is a method of applying rhinestones to garments to create sparkling, eye-catching designs.
This process involves adhering rhinestones onto the fabric to form intricate patterns or logos, giving apparel a glamorous, shining effect.
Rhinestone designs are made by placing small, shiny crystals, usually made of glass or acrylic, onto a garment using a heat press or adhesive backing. The result is a 3D effect that catches the light and adds a touch of luxury to the design.
Rhinestone prints are perfect for light fabrics like cotton or polyester and offer an excellent option for designs that need to sparkle and shine.
Gears Sphere also provides you with the convenience of rhinestone printing for your brand.
Are You Ready to Manufacture Custom Apparel for your Clothing Brand?
Click the button below to get started!