When we set out to create our activewear line, we knew the logo was going to be a big deal. It’s more than just a symbol—it’s the face of the brand, the detail people notice first, and the part that has to survive workouts, wash cycles, and everything in between. But choosing the right method to apply our logo turned out to be one of the most challenging parts of the process.

Heat press, embroidery, screen printing, sublimation—each method had its own strengths and quirks, and we wanted to get it just right. Here’s what we learned as we tested (and re-tested) different logo application methods, the pros and cons we discovered, and how we ultimately found the best fit for our activewear.

Heat Press: Affordable, But All Heat Presses Aren’t Equal

We started with heat press because it seemed like the simplest, most cost-effective solution. And honestly, it’s a great method if you’re looking for bold, vibrant logos. But as we dove deeper, we learned that not all heat press logos are created equal—there are different materials, like vinyl and silicone, that drastically change the durability and feel.

• Vinyl Heat Press: While it’s affordable and easy to apply, we found vinyl logos didn’t hold up well to intense workouts or repeated washing. Over time, the edges started peeling, especially when exposed to high heat in dryers.
• Silicone Heat Press: Silicone was a game-changer. It adhered better to the fabric, flexed naturally with movement, and was significantly more durable than vinyl. After multiple wash-and-dry cycles, silicone held up far better and kept its sleek look.

What we learned: Heat press is great for lightweight activewear and bold designs, but if you go this route, choose silicone for better durability. Vinyl is more suited for casual, low-use garments, not performance wear.

Embroidery: Premium Look, But Beware of Bulk

Embroidery has a classic, premium feel that we loved for pieces like hoodies and joggers. It gives a textured, professional finish that immediately elevates the garment. But when it came to activewear, things got tricky.

• Durability: Embroidery lasts forever. It doesn’t fade, peel, or wear out. We loved how sturdy it was, even after dozens of washes.
• Bulk and Skin Irritation: Here’s the downside—on lightweight fabrics, embroidery can feel bulky and stiff. For tighter-fitting pieces like leggings or compression tops, the stitching sometimes irritated the skin during workouts. That was a dealbreaker for us, especially for high-movement pieces.

What we learned: Embroidery is perfect for outerwear and athleisure, but not the best option for fitted performance wear.

Screen Printing: Durable but Not Indestructible

Screen printing was another method we tested, and it quickly became clear why it’s so popular. It gives you vibrant, detailed logos and lasts a long time—until it doesn’t.

• Pros: Screen printing looks amazing, especially for large, intricate designs. It also feels lightweight on the garment, which is a big plus for activewear.
• Cons: After repeated washes and drying, the heat started to take a toll. We noticed small cracks forming in the print, and over time, the logos lost their crisp look. It wasn’t immediate, but for pieces meant to endure heavy use, this was something to consider.

What we learned: Screen printing is great for lightweight, casual pieces or designs that won’t face extreme wear and tear. But for high-performance activewear, it might not stand the test of time.

Sublimation: Seamless and Sweatproof

Sublimation felt like the future of activewear logos. It’s a process where the ink is embedded directly into the fabric, so there’s no peeling, cracking, or fading. The result? A seamless, lightweight logo that feels like part of the garment itself.

• Pros: Sublimation was perfect for polyester-based fabrics (think leggings, sports bras, and performance tops). It’s incredibly durable and doesn’t add any bulk, which is a win for high-movement activities.
• Cons: The biggest limitation is fabric choice. Sublimation only works on polyester or polyester blends, so it’s not an option for cotton or other materials. It’s also better suited for lighter-colored fabrics—dark colors can muddy the design.

What we learned: Sublimation is unbeatable for performance-focused activewear, especially if you’re using polyester fabrics. But it’s not versatile enough for an entire collection.

The Verdict: What Works Best for Activewear

After all the testing, here’s what we found works best for different pieces in an activewear line:

Performance Gear (Leggings, Sports Bras, Compression Tops):

• Best Method: Sublimation
• Why: It’s lightweight, durable, and sweatproof—ideal for intense workouts.

Athleisure and Outerwear (Hoodies, Joggers, Jackets):

• Best Method: Embroidery
• Why: It gives a premium, long-lasting finish that works beautifully on thicker fabrics.

Trendy Drops (Seasonal Collections):

• Best Method: Heat Press (Silicone)
• Why: It’s affordable and works well for bold, trendy designs with a short lifespan.

Casual, Low-Impact Wear:

• Best Method: Screen Printing
• Why: It’s vibrant and lightweight, but not durable enough for heavy use.

What We Learned Along the Way

The journey of finding the perfect logo application method taught us that there’s no one-size-fits-all solution. The right method depends on the fabric, the purpose of the garment, and the durability you need.

Here’s the biggest takeaway: your logo represents your brand’s quality and identity, so don’t settle. Invest in methods that align with the purpose of your activewear, and always prioritize the customer experience—whether that’s durability, comfort, or style.

For us, every logo is a decision about how we want our customers to feel when they wear our pieces. And if it doesn’t hold up under the toughest workouts, it doesn’t make the cut.

This blog isn’t just about logos—it’s about how every decision shapes the identity of a brand. Choose wisely, and your logo will do more than stand out—it’ll stand the test of time.