Screen printing is one of the most popular methods for applying logos to activewear—and for good reason. It’s bold, versatile, and gives you the freedom to create detailed, vibrant designs that really pop on your clothing. But here’s the thing: screen printing is only as good as the technique behind it.

When we started exploring screen printing for our activewear line, we quickly realized there’s a lot more to it than just applying ink to fabric. What seemed simple at first became a lesson in the science of durability. And if you’ve ever had a screen-printed logo crack, fade, or peel after just a few washes, we’re here to explain why that happens—and how to avoid it.

The Cracking Problem: Why Some Screen Prints Don’t Last

One of the biggest frustrations we’ve seen with screen printing logos is how easily they can crack or fade over time, especially after being washed and dried on high heat. You’ve probably seen it before: a logo that starts peeling at the edges, or fine lines in the print that split after a few washes.

But why does this happen?

• Inadequate Adhesion: If the ink doesn’t fully bond to the fabric, it won’t survive the constant stretching and movement of activewear.
• Skipping Layers: Screen printing isn’t a one-and-done process. Applying a single layer of ink without proper groundwork often leads to fragile prints that don’t hold up.
• Heat Stress: Activewear goes through a lot—frequent washes, intense workouts, and (let’s be honest) trips through the dryer. Without the right process, screen prints simply can’t keep up.

What We Learned: The Key to Durable Screen Prints

After working closely with printing experts, we learned a game-changing technique that solves this cracking issue: using transparent glue as a base layer.

Here’s the process they taught us:

1. Start with Transparent Glue: Before applying the ink, use a clear, adhesive layer on the fabric. This acts as a foundation, helping the print stick better to the material.
2. Layer, Layer, Layer: Instead of applying the logo in one thick pass, it’s better to build it up gradually. Multiple thin layers ensure the print is even, flexible, and durable.
3. Cure the Layers Properly: Each layer needs time to set and cure. Rushing through this step can weaken the bond, making the print prone to cracking.
4. High-Quality Ink: Cheap ink may save money upfront, but it won’t last. Using durable, stretchable ink designed for activewear ensures the print holds up during workouts and washes.

The Role of Heat: A Hidden Enemy

One of the most surprising things we learned? Drying your activewear on high heat can damage screen-printed logos, even if they were applied perfectly. High temperatures break down the adhesive properties of the print, causing it to crack or peel over time.

How to prevent this:

• Low Heat or Air Dry: Always wash your screen-printed activewear in cold water and either air dry it or use the lowest heat setting on your dryer.
• Avoid Stretching Prints: Pulling or over-stretching garments with screen-printed logos can weaken the bond between the print and fabric, so treat them gently.

Why Screen Printing Still Holds Up

Even with its challenges, screen printing remains a fantastic option for activewear logos—if done correctly. It allows for vibrant colors, intricate designs, and a professional finish that works across a variety of fabrics. And with the right preparation (hello, transparent glue base!), it can last for years.

What makes it stand out:

• Vibrant Colors: Screen printing creates bold, eye-catching logos that don’t fade easily.
• Customizable Designs: Whether it’s a large graphic or a small, detailed logo, screen printing can handle it all.
• Cost-Effective for Large Orders: While setup can be time-consuming, it’s a great option for producing consistent, high-quality prints in bulk.

What We’ll Do Differently Moving Forward

After diving into the world of screen printing, we’ve fine-tuned our process to ensure our logos are built to last. Here’s how:

• Always Use a Base Layer: Transparent glue is now a non-negotiable for us. It’s the secret to creating prints that bond tightly to fabric and resist cracking.
• Focus on Thin, Even Layers: Instead of rushing the process, we apply multiple thin layers of ink to ensure flexibility and durability.
• Partner with Experts: Finding a screen printing partner who understands the specific needs of activewear has been a game-changer. They know how to work with stretchy fabrics and handle the curing process properly.

Is Screen Printing Right for Activewear?

Absolutely—when done correctly. Screen printing is a fantastic choice for activewear logos that need to stand out, but it’s not a “set it and forget it” process. It requires careful preparation, high-quality materials, and proper care to ensure the designs hold up over time.

Best for:

• Bold, colorful designs that demand attention.
• Logos on medium to thick fabrics (e.g., hoodies, joggers, or outerwear).\
• Bulk orders where consistency is key.

Avoid if:

• Your activewear pieces are ultra-thin or require logos that stretch significantly. Sublimation or silicone heat press may be better for these cases.

Final Thoughts

Screen printing taught us that even small details—like using transparent glue or applying multiple layers—can make a big difference in the quality and longevity of a logo. It’s not the quickest method, but when done right, it creates vibrant, durable designs that stand the test of time.

If you’re considering screen printing for your activewear line, remember: the foundation matters. Lay the groundwork properly, use high-quality materials, and treat your prints with care. Your customers will notice—and thank you—for the attention to detail.

Have questions about screen printing or tips you’ve learned? Drop them in the comments below!