Decoration · Cap Encyclopedia
Sublimated Caps
Dye-sublimation prints unlimited colours edge-to-edge on polyester panels before they're sewn into a cap. Colour is dyed into the fibre — nothing sits on the surface, so it never cracks, peels or fades. The right process for photographic art, gradients and full-panel graphics.
Fabric
100% polyester
Or high-poly blend
Colours
Unlimited
Photo + gradient OK
Process
Panel-flat print
Before assembly
MOQ
100–200 pcs
Per design
How sublimation on caps works
- Artwork is separated by panel — each cap panel has its own printed piece.
- Design is printed onto transfer paper with sublimation ink.
- Paper is pressed onto pre-cut polyester panel fabric at ~200°C.
- Ink turns to gas and bonds into the polyester fibres — the print becomes part of the fabric.
- Printed panels are then cut and sewn into the finished cap.
Where sublimation fits best
| Silhouette | Fit | Note |
|---|---|---|
| Trucker (poly front) | Ideal | Foam front takes ink perfectly |
| Running / performance cap | Ideal | Polyester substrate, tech look |
| Team-issue 5-panel | Ideal | Panel graphics without seam disruption |
| Wool blend snapback | Not suitable | Wool won't take sublimation |
| Cotton dad hat | Not suitable | Sublimation needs polyester |
| Bucket hat (poly canvas) | Good | Watch seam alignment on wall |
Design rules for sublimation
- Design panel-flat with 5mm seam allowance — art that must line up across a seam needs the seam allowance plotted.
- Colour: only white polyester holds true colour. Any base tone shifts the palette.
- Provide 300 DPI files at panel size; vector preferred where possible.
- Blacks: use rich blacks (C60 M50 Y50 K100) — pure K prints muddy on polyester.
- Neons and fluorescents: available in extended ink sets; confirm with sample.
- No white ink — sublimation cannot print white; anywhere that reads white is unprinted base fabric.
MOQ & timeline
- MOQ: 100–200 caps per design. Sublimation is per-piece printed — no plate or screen tooling.
- One design or one hundred designs per PO cost the same per unit — mixed programmes are efficient.
- Sampling: 7–10 working days for panel-flat print sample plus one sewn cap.
- Bulk: 25–35 days after PP approval.
Common pitfalls
- Trying to sublimate on cotton or wool — impossible. Confirm every panel spec is polyester.
- Ignoring seam alignment — full-crown graphics must be plotted panel-by-panel with seam offset.
- Expecting a pure white area to match Pantone — white is the unprinted fabric; batches shift.
- Skipping the panel-flat print sample and going straight to sewn — colour is much easier to correct at flat stage.
Full-panel sublimated caps?
Send the artwork; we'll return a panel-flat print sample plus a sewn cap in your chosen silhouette.