What happens once you place an order. 

At Black Sorrows we don't carry any stock. So when you make an order we start to make it, better known as 'made to order' and we get to work straight away. Here's what happens. 

Our talented team of Sublimation experts print the design onto a large sheet of dye sublimation paper.

Then, the design is pressed at high temperatures of around 180 to 210 °C (356 to 410 °F) directly onto the fabric that we are going to use to create your product.

Now that we have the large pieces of fabric ready with the design on them, we can cut it to shape and sew it together seamlessly. That's how we get such an amazing finish with cut & sew sublimation.

How we create our products. 

There’s a few different printing methods that are used to bring designs to life on apparel, homewares, accessories and more.

One such method is called cut and sew sublimation and here at Black Sorrows, it's our specialty! It's actually the method we use the most. In this article you’ll discover why it’s the best method for printing high quality, long lasting products.

To explain the process from a very basic point of view, the cut & sew sublimation process involves printing designs on sublimation paper and then transferring them to fabric using heat and pressure.

There's more to it though and there are even other sublimation methods that are not the same as cut and sew, but we'll talk about that later. 

The process of cut & sew sublimation is literally exactly as it sounds. The products are cut and sewn together, but not before the printing part of the process has happened. 

What Are The Benefits of Cut & Sew Sublimation?

The most obvious advantage of any form of sublimation, especially cut & sew, is the ability to print over the entire garment. Hence the name, "all over print".

With cut & sew sublimation you get the added advantage of a seamless finish with no unsightly white creases or patches.

Advantages of Cut & Sew Sublimation 

  • Seamless, all over print finish
  • Vibrant, high definition colors
  • Very durable print with no cracking or peeling
  • Matching thread colors for certain products
  • Long lasting two way stretch material

So What is 'Regular' Sublimation?

As we just discussed, not all sublimation is the same. So what exactly is 'regular' sublimation then?

Regular sublimation is a printing process that uses dye-sub inks and a heat transfer process just like cut & sew sublimation, but the dye sublimation paper is pressed directly onto the product.

This is fine for products such as mugs, phone cases, and coasters. But when it comes to clothing, there can be issues.

If you can imagine a blank t-shirt laying flat ready for pressing, then you might realize that the finish certainly isn't going to be perfect.

As you can see from the image above, some areas of a regular sublimated t-shirt are never going to have a perfectly pressed finish so you often get creases and patches where none of the design has actually transferred onto the garment.

What About Direct-to-Garment Printing vs Cut & Sew Sublimation?

There really is a huge difference between Direct-to-Garment (DTG) printing and cut & sew sublimation.

DTG printing is the typical kind of print you would expect when ordering a standard t-shirt or hoodie with a single print on the front or back.

The DTG method uses special digital printers to print directly onto a garment, making it a very popular choice in the printing industry and even amongst amateur home-based printing businesses.

The garments that are used for DTG printing are also pre-made and sourced from big clothing manufacturers like Gildan and Hanes. They also come in various colors direct from the manufacturer, pre-dyed just like the mass-produced apparel you might find in a department store.


Now you have a better understanding of cut and sew sublimation, there's a good chance that you know why we're so passionate about it.

Sure, there'll always be a market for DTG garments but there's so many companies out there putting out below-par quality products for rock-bottom prices that we just aren't interested in doing something that we can't be proud of.

That's why here at Black Sorrows we are always pushing innovative boundaries and delivering unbeatable quality products, state-of-the art app technology and amazing user-experiences.

Thanks so much for taking the time to read this, we hope that it has given you an improved understanding of how our products are made and how cut and sew sublimation works.

For more information you can contact us at help@blacksorrows.com