Flex Printing vs. Sublimation Printing: Pros and Cons Compared

Flex printing: what exactly is it?

Would you like to know more about the flex printing process? In this article, we explain the advantages and disadvantages of this well-known printing process.

spized | Clothing and equipment

May 14, 2024 |

Whats’ on this page

1. What is flex printing?

2. How does flex printing work in practice?

3. Advantages of flex printing

4. Disadvantages of flex printing

5. Das Sublimationsdruckverfahren ist eine hochwertige Alternative

6. The advantages of the sublimation printing process at a glance

7. Flex printing in sport

What is flex printing?

Flex printing is a flexible printing process in which a template is applied to film and then cut to size using a cutting plotter. The process is similar to the classic flock process and is often referred to as a ‘simple version’ of flock printing. The print motif consists of one to three different foil components, which is why the individual foils must first be brought into the shape of the motif.

How does flex printing work in practice?

Flex printing is a popular printing process that is used by many suppliers for jersey and textile finishing. The printing film is durable and is characterised by a smooth and subtly glossy surface. In practice, the flex printing process usually involves 5 steps:

Firstly, the film is placed in the cutting plotter, which uses software to transfer the contours of the motif onto the film and cut it out.
After cutting, a piece of plotting film remains on which the motif is already easily recognisable.
Now it is weeded. This means that the motif is manually cut out with a hooked needle and excess film is removed. The motif remains on a transparent carrier film.
The film is now placed on the textile using a press. Heat and pressure ensure that the flex film transfers the motif to the jersey or textile.
Approximately 15 seconds later, the backing film is removed and the flex print jersey is ready.

Advantages of flex printing

1) Good results with texts, fonts, numbers and simple logos

With flex printing, the motif is welded onto the textile using coloured films. Texts, lettering, numbers and simple logos are accordingly well presented with this process.

2) Ideally suited for cotton textiles

The printing film is slightly thicker in the flex printing process, meaning that the motif can be placed easily on cotton textiles. If the colours and fine lines of the motifs are limited, flex printing does not restrict wearer comfort. If large motifs are to be printed on polyester fabrics (e.g. jerseys), the flex film impairs the breathability of the textile.

3) High availability

Flex printing is a classic printing process that is offered in numerous online shops or specialist sports shops. If you want to have a jersey printed using the flex printing process, you won't have to look far.

4) Cost-effective for small print runs

In principle, each individual print component (e.g. number, logo, club name) costs a corresponding surcharge. For small print runs, this surcharge is only of minor importance. Even for a single jersey set, the additional costs for individual flock components are not particularly noticeable. This printing process becomes more expensive when multi-coloured sponsors, several flock components are to be placed and/or a large number of jerseys are to be purchased.

Disadvantages of flex printing

1) Limited design options

Flex printing can generally only place three colours per motif on the textile. In addition, particularly large motifs affect the material properties of the textile. Photographs, complex patterns and multi-coloured graphics are also not possible with the flex printing process.

2) Durability

In principle, textiles designed using the flex printing process are machine washable. However, both the flock and the material properties (e.g. breathability) do not last forever. At some point, the colours fade due to frequent washing and the adhesive becomes porous, causing the fibres to break.

3) Wearing comfort

The motifs are welded onto the jersey or textile. Regardless of the size of the motif and the textile material, this process always puts a strain on the material properties of the product. In addition, the flex film is very thick, which means that the motifs may be noticeable on thin fabrics (e.g. jerseys). Both of these factors considerably reduce the wearing comfort.

4) Effort and delivery times

In the penultimate process step, the film is weeded by hand and the motifs are welded onto the textile using a transfer press. The more components to be printed, the more time is required. Combined with high demand, delivery times of four to six weeks are not uncommon. With the flex printing process, you therefore need a little patience or lead time after placing your order.

5) Price for large print runs

A football team usually has 25 players who each need a kit for home and away games. In football, four flock components (club name, number, crest and sponsor) are mandatory or standard.

An example calculation: If we assume the average price of a standard jersey (€20) and add the four flock components for a surcharge of €5 each, a jersey with the flex printing process costs €40. If we add the away jersey, the cost per player is 80 euros. In this example calculation, the total cost for the team is €4,000 if two sets of jerseys (home and away jersey) are required for 25 players. This is much cheaper!

Das Sublimationsdruckverfahren ist eine hochwertige Alternative

The flex printing process is a widely used method for embellishing jerseys. However, it has some disadvantages in terms of cost, design and durability, which the sublimation printing process can solve.

Sublimation printing is a completely digital process, so there is no additional work and therefore no extra costs for complex patterns and multiple flock components. This makes sublimation printing attractive not only in terms of quality, but also when it comes to pricing large print runs. If we take the previous calculation example as a basis, the total costs for two jersey sets with four flock components are as follows:

35 euros per jersey and 0 euros surcharge for the desired motifs. The total cost (home and away jersey) is therefore 70 euros per player or 3,500 euros per team. The sublimation printing process at spized therefore saves your team a whopping 500 euros.

In addition, with sublimation printing, the colours are vaporised into the textile. This means that there is no adhesive that can come off at some point or coloured fibres that fade after a few washes.

The advantages of the sublimation printing process at a glance

Individual designs: multi-coloured motifs, logos and coats of arms can be easily reproduced on the jersey. When it comes to design freedom, there is no better printing process!
Print quality: Evaporation ensures that patterns, graphics and photographs are displayed with maximum colour intensity.
Material properties: No coating is left on the jersey during vaporisation. As a result, the textile retains its original material properties, such as breathability.
Durability: The colour intensity remains high even after numerous washes. Here too, no other printing process can keep up.
Delivery times: Sublimation printing is a completely digital process, which shortens the production time. At spized, we deliver your ordered jerseys within 14 days.
Pricing: Sublimation printing is often cheaper, especially for large print runs, because there are no additional costs for motifs. With spized, you can place as many components as you like - at no extra cost.
Water-based colours: Sublimation printing does not require any binding agents or solvents. Water-based colours are a much more environmentally friendly alternative.

Would you like to find out more about jersey printing or jersey flocking? Find out everything you need to know here.

Flex printing in sport

In many sports clubs, the teams or parents, players and coaches are more or less responsible for buying their own jerseys. As a rule, there is no standardised system and a lot of micro-sponsoring, so simple or quick solutions are sought when printing the jerseys. Flock and flex printing are well-known processes that are widely available on the internet and in retail outlets. And as long as the print runs remain low, the costs are also at a manageable level.

The flex printing process also delivers respectable results for simple coats of arms and logos as well as lettering and numbers. Unless a complex sponsor logo is to be placed, the parties involved are initially satisfied after delivery. The disadvantages of the flex printing process often only become apparent after one or two seasons with the new jersey have passed. The flock usually starts to peel and the colours become increasingly visible. In addition, athletes notice that the material properties deteriorate and breathability is limited.

Individual new orders are then quickly needed, but these are often no longer available from the manufacturer because the model once selected is no longer in production. At this point at the latest, the factors (quality, durability, design, costs and delivery time) are discussed again and cost-effective alternatives are considered.