How to Source Custom Sports Jerseys: Sublimation, Numbers, and Team Sizing

A sports jersey is the one garment where the decoration is not decoration. The number and the name are the product, they are read from thirty metres away, and they must survive a season of washing and a season of being grabbed. Get the number sizing wrong and the whole batch is unusable, because a size L jersey with a size S number on the back looks like a costume. This guide covers how to specify a jersey that fits a roster, prints cleanly, and arrives with every player identifiable.

The 6 decisions that define a jersey

Fabric: mesh is not a fabric, it is a construction

The mesh options

Double mesh is the default for a reason

A single-mesh jersey is one layer of open knit. It is breathable and it is cheap, and it has two problems: the number printed on it shows through from the front, and it is transparent under a floodlight. Double mesh solves both: the solid interlock back is what the number is printed onto, so the front stays clean, and the solid back is what makes the jersey opaque. If a factory quotes you a single mesh for a basketball jersey with a front number, ask what is behind the number. If the answer is nothing, the number will read through.

What to specify

• Composition with percentages: 100% polyester is the norm for team wear
• Weight in gsm: 140-160 for single mesh, 160-220 for double mesh
• Construction: single mesh, double mesh, interlock, tri-blend
• Width: 150 cm or more for a body panel plus sleeve in one cutting, which reduces panel count and seam bulk
• Stretch and recovery: the body needs 4-way stretch of at least 30% with good recovery, because a player reaches and the fabric has to come back
• Moisture management: if a wicking finish is applied, ask how many washes it is rated for

Decoration: why sublimation wins for names and numbers

The decoration method on a jersey is decided by one constraint: the design must not crack, peel, or change colour over a season of washing, and it must be readable from distance.

The comparison

Why sublimation is the right answer

Sublimation dye bonds with polyester fibres under heat and pressure. The dye becomes part of the fabric rather than a layer on top, which means:

• It cannot crack or peel, because there is nothing sitting on the surface to crack
• It stretches with the fabric, so a number on a single-piece mesh panel does not distort when the player moves
• Unlimited colours and no setup cost, which is why it works for 15 different player names in one order
• Full-colour crests and photographic logos are possible, which matters for a club with a detailed badge

Two constraints follow from sublimation: the fabric must be polyester (the dye has nothing to bond to in cotton), and the white areas of the design must stay white, which means the base garment must be white or the areas you want white must be knocked out in the artwork. That second point is where most first-time orders go wrong, and it is why a white polyester base is the standard choice for a sublimated jersey with a coloured number.

Handling white in a sublimated design

• Base fabric in white, and the coloured number is the only ink transferred
• Or the design file is prepared with the white areas as no-transfer, and the base is the light colour
• For a full-colour design on a coloured base, the base must be white or very pale

Combining methods

Most real jerseys combine two or three methods, and the split should follow what each part does:

• Numbers and names: sublimation. They stretch, they are read from distance, they must not crack
• Team crest: sublimation if it is full colour, screen print if it is one or two spot colours, embroidery for a premium woven look
• Sponsor marks: heat transfer or sublimation depending on the number of sponsors
• Player name on the back: sublimation, always

Number sizing: the rule most first-time buyers get wrong

This is the single most consequential specification on a jersey, and it is almost never written down in the first order.

Jerseys are sized by chest, not by height

A basketball jersey does not come in a “medium”. It comes in a chest measurement, because the garment must fit a range of body types and the number must match the body it sits on.

The size chart

Why the numbers are so much larger than the body

The number on a size L jersey is 41 cm tall on a jersey whose body is 78 cm long. That ratio is not decorative. Three reasons force it:

• Readability at distance: a number has to be legible from the back row of a stadium. A “correct” proportional number on a small chest is unreadable in practice
• Single-piece construction: on a sublimated jersey the number is one printed piece, not a stitched-on patch. It is printed across the full width of the back panel, so the number width is bounded by the chest width, not by a patch
• Stretch and drape: a large printed area on a stretch mesh panel distorts with movement, so the artwork is drafted slightly narrower than the finished number to compensate

The enlargement rule

The number is graded against the chest measurement, and a useful working rule for the height is:

• Number height approximately equals 38% to 42% of the jersey length
• Number width approximately equals 68% to 72% of the chest width
• Name height is usually 20 to 26% of the jersey length, in a condensed uppercase font

These ratios are what a factory uses to draft the artwork. If you specify the number height directly for each size and the factory drafts it to your chest width, you get a consistent set. If you specify only “large numbers”, you get a set that drifts from size to size.

The graded artwork package

The correct way to brief this is to ask the factory for a graded artwork package:

• One master artwork file per number, drafted per size
• Each size’s artwork includes the number and the name in the correct position
• Placement coordinates, usually measured from the collar seam or the hem

This is a 15-30 minute job per number for a competent factory, and it is included in most quotes. Ask for it explicitly. A factory that produces one artwork and scales it proportionally will produce numbers that are too small on the large sizes and too large on the small sizes, which is exactly the drift that makes a team look amateur.

Names: the specification that is missed

• Spelling: confirm every player’s name in writing before production. A misspelled name on a jersey that ships to a 12-year-old is a real cost, not a small error
• Capitalisation: upper case is standard for surnames, and it is easier to read from distance
• Font: a condensed uppercase font with simple letterforms. Serifs, script fonts, and letters with thin strokes fail in sublimation because the dye does not transfer reliably on thin areas
• Minimum stroke width: about 2.5-3 mm at the final size. Below that the transfer breaks up and the name goes patchy
• Arc or straight: an arched name follows the shoulder line and is traditional; a straight name is cleaner and more modern. Specify which
• Letter spacing: specify it, because default tracking in a design tool is often too wide for a name panel

Number and name placement

Position is measured from the collar seam down, or from the hem up, and it must be stated. A number that sits too high crowds the name; too low and it rides up when the player moves.

Trim and construction

Collar types

Sleeves and cuffs

• Sleeveless: common in basketball and training. Specify the armhole binding
• Short sleeve: the standard for most team wear
• Cuff: rib cuff matching the collar, or a self-fabric hem
• Side panels: contrast panels or piping down the side, common in modern team wear. Specify the panel width, usually 4-6 cm, and the fabric

Fit

Modern basketball jerseys are oversized, and players expect that. Specifying a trim fit because that is what a technical drawing showed is a common first-order error: the order arrives, the team says it feels like a costume, and it has to be reordered.

Ordering by roster: the real workflow

A team order is not a style order. It is a list of individual people, each with a size and a name and a number.

What to ask the team for

• Player name, spelled correctly, per person
• Number per person, and whether it is a personal choice or assigned
• Size per person, by chest measurement, not by “S/M/L” intuition
• Any special requirements: a captain’s armband, a different colour for the goalie, a longer cut for one player, a child’s size in the same order

Size distribution for a typical team

The critical packaging requirement

Each jersey must be individually poly-bagged with the player’s name visible on the bag, because the team manager distributes them. If 15 jerseys arrive in one carton and the names are on the backs, somebody will hand the wrong one to the wrong player and it will be a photograph on someone’s phone for the rest of the season.

• One garment per poly bag, never a multi-pack
• A name label on the outside of the bag: a printed sticker or a small tag with the player’s name
• Name labels on the garment too, so it is identifiable after the first wash
• Bagged in name order inside the carton, so the manager can hand them out in a line

This is a small packaging instruction that almost every first-time team order misses, and it is the difference between a smooth distribution night and an argument in a car park.

Sets and mixed quantities

• Home and away: two designs means two dye lots, two artwork sets, and twice the MOQ per design
• Names and numbers kit: often sold separately as a pack of iron-on numbers and names, for teams that change players
• Extra goalkeeper or alternate jerseys: these must be the same size as the roster, not a separate size run
• Practice jerseys: often a simpler design, and a separate MOQ

Cost breakdown

Realistic FOB cost for a 20-piece team order of double-mesh basketball jerseys, sublimated number and name per player, a one-colour sublimated crest, ribbed crew collar, and individually name-labelled poly bags:

What moves the cost on jerseys

• Number sizing: standard to enlarged is 0.30-1.20 USD per piece, and it is a labour cost, not a material cost
• Decoration area: a full-bleed back print costs more than a small crest, because the press time scales with area
• Fabric: single mesh to triple mesh is 0.60-1.10 USD
• Order size: a 20-piece order carries the full setup and grading cost across 20 garments, which is why a 20-piece team order costs 2-3x per unit what a 200-piece bulk order does
• Number of distinct designs: home and away doubles the artwork, the dye lot, and the MOQ

MOQ and lead time for jerseys

Important: team wear breaks the usual MOQ logic. A single apparel MOQ of 500 pieces does not apply to a 15-player basketball team. Factories that work with clubs and leagues accept 30 to 50 pieces because the design work, not the fabric, is the constraint. The factory’s MOQ for a single team order is usually lower than for a wholesale programme, but the per-unit cost is higher because the setup does not spread.

8 mistakes that cost jersey buyers money

1. Not specifying the number size per size — a number that fits an S player will be unreadable on an L, and a proportionally scaled set drifts from size to size. Specify a number height per size, or request a graded artwork package.
2. Letting the factory scale one artwork — proportional scaling makes the small sizes look oversized and the large sizes look undersized. Ask for the graded artwork files and check them before approving.
3. Using a font with thin strokes — sublimation does not transfer reliably below about 3 mm, so a fine serif or a script name goes patchy. Specify a condensed uppercase font.
4. Forgetting the names are sublimated and the crest is not — mixing a screen-printed number with a sublimated name looks like two different products on the same shirt
5. Not packing one garment per bag with a name label — the team manager cannot distribute 15 jerseys from a carton, and someone gets the wrong number
6. Ordering a trim fit — modern basketball jerseys are oversized, and players expect that. Specify relaxed or oversized unless the sport demands otherwise.
7. Using cotton or a cotton blend for sublimation — the dye has no polyester to bond to, and the design will not transfer
8. Not confirming the names in writing — a misspelled name on a youth team jersey is an expensive mistake, and it is entirely preventable with a signed roster

Quality checks specific to jerseys

Add these to the inspection brief, because a generic garment inspection misses all of them:

• Number and name spelling: check every one against the signed roster. This is checked on 100% of units, not a sample, because a misspelling is not a rate
• Number size: measure the number height and width on each size against the spec, and confirm the ratio to the chest and the jersey length
• Number placement: the number sits at the specified distance from the collar seam, and it is centred
• Sublimation quality: the dye has fully penetrated with no pinholes, no pale patches, no white halo around letter edges, and no lifting at the edges
• Colour: matches the approved artwork and the Pantone reference for spot colours, with no shade drift across the batch
• Stretch test on the print: stretch the panel 30% and confirm the number distorts proportionally and returns, with no cracking
• Mesh opacity: the back is opaque under light, and the number does not show through from the front
• Collar and cuffs: rib is the right size, recovers after stretching, and does not roll
• Packaging: one garment per bag, name label present and legible, bagged in name order

How to structure the inspection request is covered in our QC and AQL guide, and the operational version is in Step 4: QC Inspection.

Packaging for jerseys

• One garment per poly bag, 0.04-0.05 mm, with the player’s name printed on the outside of the bag
• Folded in quarters with the number on top, so the name and number are visible when the bag is opened
• Master carton sized to 20-30 garments, with the carton marked by team and by the number range inside
• Typical unit load: 40-60 jerseys per master carton

Carton and container math is in our packaging and container optimization guide.

FAQ

How are custom sports jerseys priced?

FOB from China, a 20-piece team order of double-mesh basketball jerseys with a sublimated number and name and a one-colour crest: roughly 10-14 USD per piece. Blank jerseys without decoration run 4.50-6.00 USD. A 200-piece wholesale programme with the same design lands closer to 6-8 USD, because the artwork, the grading, and the setup spread across the run. For the general cost model, see our pricing guide.

What size should the number be?

Graded by chest, at roughly 38-42% of the jersey length in height and 68-72% of the chest width. A size L basketball jersey is 78 cm long with a 41 cm number. The critical rule is to give a number height per size rather than saying “large numbers”, because a proportionally scaled set drifts from size to size and the small sizes look clumsy.

Can I mix sizes in one order?

Yes, and that is normal for team wear. The MOQ applies per style per colour, not per size, so a 20-piece order across 5 sizes is 20 pieces. The practical constraint is that some factories require a minimum of 5-10 pieces per size, so a roster with one player in a 2XL needs to be discussed in advance. Our sizing and grading guide covers the chest-measurement approach in detail.

Why does sublimation require polyester?

Sublimation dye is dispersed into the fibre under heat and pressure, and it only bonds with polyester. On cotton it will not transfer at all, and on a cotton blend it transfers unevenly, leaving a hazy print. If you need a cotton hand feel, the decoration method has to be screen print or heat transfer instead, which is a different design decision.

How do I avoid trademark problems with team jerseys?

Do not reproduce league or club logos, team names, or sponsor marks you do not have permission to use. Legitimate approaches: use your own club name and a crest you own, use generic team names for a private league, and order blank jerseys and let each player or the league apply the marks. Screen printing and heat transfer exist precisely so a club can add its own branding to a blank jersey. This is also worth a line in your customer-facing terms, because a buyer who does not know the rule will ask you.

How many sample rounds do jerseys need?

One to two for a single design with a fixed roster. The sample is mainly to confirm the number size, the placement, and the colour, and it should be a size L or XL so the numbers are visible at full scale. A small-size sample hides sizing problems, because a number on a youth jersey fills the whole back and looks fine at any size.

What is the lead time for a team order?

50-70 days for blank jerseys and 60-80 days with names and numbers, from the order to the warehouse. If the order is for a season starting in November, it needs to be placed by August. Youth sports seasons start sharply in September and October, and a factory’s capacity for team wear fills up in July and August, so early booking matters more here than for most apparel. The lead times guide has the stage-by-stage breakdown.

Can I get names and numbers as a separate kit?

Yes. Iron-on or heat-transfer numbers and names are sold separately, which is useful for leagues where players change between seasons. The trade-off is durability: a heat-transfer number peels after 25-50 washes, and a sublimated number lasts the life of the garment. If the kit is for a single season, heat transfer is fine and cheaper. If it is for a club that keeps jerseys for years, sublimation on new jerseys is the better spend.

How this fits the buyer journey

Everything in the general cluster applies. These are the ones that matter most for jerseys:

• Custom Apparel Sizing — the chest-measurement sizing and grading behind the numbers
• Decoration Methods Compared — sublimation against screen print, DTG, and heat transfer
• Custom Fabric Development — mesh constructions, weight, stretch and recovery
• Color and Dye Development — matching the number, the crest, and the base fabric
• Trims and Labels — rib trims, the name label, and the fibre content rules
• Custom Apparel Pricing — what moves the cost per jersey
• MOQ Guide — why team wear breaks the usual MOQ logic
• Lead Times — season timing and peak capacity
• Quality Control and AQL — the theory behind the inspection checks
• Step 4: QC Inspection — how to run the inspection on a printed garment
• Packaging and Container Optimization — one bag per garment, carton marking
• Workwear and Uniforms — the roster-based ordering model, for comparison
• Activewear — performance fabrics, wicking, and seamless knits
• Hoodies and Sweatshirts — rib trims and fleece shells
• Custom Jackets and Outerwear — collar and interlining construction
• How to Write a Tech Pack — where the number sizing spec belongs
• The 5-Step Custom Apparel Process — the framework the order runs through

How we work at Kemondo

At Kemondo Apparel, team wear is a regular part of what we make, and the specification discipline is the same as for any other garment, applied to the parts that matter in sport. Our standard team jersey is 160 gsm double-mesh polyester with a ribbed crew collar, graded artwork per size, and sublimation for the number and the name. We produce the graded artwork package rather than scaling one file, and we send it to you before production so you can check the number size on the small and the large. Every unit is checked against the signed roster for spelling, and the roster is a document we require before we cut. We bag every jersey individually with the player’s name printed on the outside of the bag and pack the carton in name order, because we have seen what happens when that is skipped. We work with single-digit MOQs for club orders and tell you honestly when a roster is too small for the setup to be economical, and when a 20-piece order costs more per unit than a 200-piece programme on the same design. And we will say plainly when a design will not work in sublimation, rather than taking the order and sending you a jersey with a patchy name.

Planning a team order and want a real quote? Message us on WhatsApp with the sport, the roster size, the size range, and whether you need names and numbers. We usually reply within 12 hours with a full cost breakdown and a realistic delivery date against your season start.