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Printing on Hanes - Tips

Home / Printing on Hanes - Tips

Embellishing Polyester Performance Fabrics - Sublimation


Calibrate equipment: make sure machines settings, start up as suggested and press do not
exceed temperatures recommended below.

The template board attached to the table is clean and free of marks.

Garment is inserted properly.

Pads (02) must be exactly art size to be transferred and place underneath area to be transferred.

No additional paper on top of garments or cushion underneath are added to the process.

Proceed transferring & removal of printed paper immediately.

Hanes Cool Dry products : plain-sportswear-clothing.html

Sublimation Printing Table

*** No Max -- are the thermal pads

Sublimation results will depend mainly on: quality of printed-paper used, temperature (heat), pressure, dwell time, humidity and other environmental conditions.

Improper machine set up will result on garment damage such as: fabric scorching & undesirable effects such as ghosting, among others.

Due to manufacturing companies of all nationalities on the market, equipment & calibrations are subject to variances, being virtually impossible to provide exactly settings.

Settings above recommended based on trials in observance of our fabric weights & other specifics characteristics

Embellishing Cotton Blend Fabrics - Print

Printing on Neon Colour

Our X-temp® t-shirt has the soft hand of cotton due to its 60% ring-spun cotton / 40% polyester blend, but it’s still best to use inks designed for polyester garments when embellishing.
Hanes X-temp® t-shirts come in popular neon colors that should be treated differently during the printing process. For best results, keep these tips in mind:

Use high performance polyester inks that cure at ink film temperature of under 300 degrees Fahrenheit and keep dryer temperatures to a minimum. Minimize flash curing time and temperature.

The print instructions apply to the following 2014 and 2015 X-temp Styles:

2014 Style 4200 X-temp® Unisex Performance T-Shirt
- Colors: Neon Orange Heather NN, Neon Lime Heather N7 and Neon Lemon Heather NZ

2015 Style 420Y Youth X-temp® T-shirt
- Colors: Neon Orange Heather NN, Neon Lime Heather N7 and Neon Lemon Heather NZ

2015 Style 42V0 Women’s X-temp® V-neck
- Colors: Neon Orange Heather NN, Neon Lime Heather N7 and Neon Lemon Heather NZ

2015 Style 42X0 Men’s X-temp® Sportshirt
- Color: Neon Lemon Heather NZ

2015 Style 43X0 Women’s X-temp® Sportshirt
- Color: Neon Lemon Heather NZ

Embellishing Polyester Performance Fabrics - Print

Challenges with Printing on Polyester

Whenever possible, sample the design with a pre-production sample to ensure the performance of the garment and decorating materials. This may include washing samples after printing to check on durability and adherence. Proper temperature is critical for curing inks as well as avoiding damaged garments, and you may experience changes with temperature or humidity shifts. You will probably have to make changes when going from 100% cotton production to polyester or poly/cotton production.

Heat Sensitivity

Polyester fabrics are more sensitive to heat than cotton fabrics. Cotton products tend to shrink after being washed and dried, where polyester products are prone to shrink when initially subjected to heat. To properly screen print on polyester it is important to control and manage your heat during the curing process. Too much heat can damage a garment in several ways including excessive shrinkage, dye migration, and scorching. You may need to use printing inks that have been formulated to cure at lower temperatures. Exposing polyester products to high temperature risks the quality issues mentioned above. You should monitor the surface temperature of the garments being cured with a thermoprobe, temperature tapes, and/or a pyrometer. Please also follow the print parameters set by the ink manufacturer.

Dye Migration

Temperatures needed to cure screen printing inks or apply heat transfers may also convert some of the dyes in the polyester into a gas. If this occurs, the polyester dyes could permeate into the ink or transfer and change its original shade. To avoid this, it is highly recommended to use inks or transfers that are bleed resistant. Dye migration can be apparent almost instantly or
could take several hours or even several days to manifest. It’s particularly advisable to wait at least 24 hours before shipping a finished product if you are unfamiliar with the garment, inks or transfers.

Embellishing Polyester Performance Fabrics - Embroidery

Embellishing Polyester Performance Fabrics


Polyester performance apparel can be embroidered just as easily as cotton apparel with just a few minor adjustments in equipment or processes.


Using a ball point needle will help to avoid cutting the fabric when running an embroidery logo. Also consider using a 70/10 needle when running on lighter weight performance fabrics


Polyester and Rayon threads are both fine to use, but a Rayon thread may actually look and feel a little better on the lighter weight fabrics due to its softer hand. Regardless of which type of thread used, a #40 thread is probably best when used with the 70/10 needles.


Stick with backings that are lighter than 2.0 oz. Tear away and cut away backings are both good, but always cut away the backing when cleaning up the logo. Pulling on the backing to remove it may lead to stretching or distorting some lighter weight fabrics.

Stitch Density

Too many stitches in a logo intended for performance apparel could result in puckering and even needle cuts. Reduce the overall stitch density and focus more on the underlay. Proper underlay coverage will help with stability as well as help with coverage when reducing the density of the step fill or satin stitch.


Hooping performance apparel too tightly may result in hoop burns, damaged fabric, or puckering in the embroidery. Hoop the garment just tight enough to stay within the hoop when being embellished without forcing the garment into the hoop. Also, do not try to adjust the fabric after it has already been hooped.