Six Great Ways to Win With Team Uniform Numbering

Use this overview to pick the best method for your shop. April 01, 2009
By Bob Robinson, Contributing Writer

Screen printing numbers can be done via stencils or an inline machine. The inline machine provides speed and accuracy, according to Bob Smothers, owner of Sport Designs & Graphics, Effingham, Ill.

There are about as many ways to number athletic team uniforms as there are teams in the ever-expanding playoffs of professional sports — in other words, lots. But you have to know which decoration process works best in various situations. With that in mind, here's an in-depth look at the six main ways to number uniforms, as well as the pros and cons of each process.

Precut Numbers

There aren't many materials options for precut numbers, at least not compared to the variety of materials available for other processes. Generally, you'll use either a polyvinyl chloride (PVC) or polyurethane (PU) film. PVC is heavier and sturdier, and PU film is thinner, has a softer hand and provides more of a screen printed look. Using lighter material allows you to print multiple layers without adding too much weight to the finished uniform. The trend in recent years has been toward lightweight, slick designs that aren't as bulky. These are ordered precut and prespaced from a supplier.

Advantages: This option is probably the most popular and enduring of the various processes for applying numbers to uniforms. A primary advantage of using precut numbers is their low cost, the result of better yield when numbers are cut in volume. In fact, precut numbers are probably the least expensive of all six processes.

Disadvantages: You may spend additional time spacing letters perfectly. Also, because you're buying the precut numbers in packages, there's the risk that you'll have unused inventory in your shop. For instance, you might end up with lots of purple Zs and Qs. Alternatively, you might not order enough of the numbers and letters you need, thus finding yourself short.

Cost and labor comparison: Generally, you'll purchase precut numbers in packages of 10 or so, an efficiency that helps control costs. When it comes to lettering, this process is actually somewhat more labor-intensive than CAD-cut numbers. That's because, if you're cutting letters yourself, spacing is automatic and perfect every time. This is less of an issue with numbering, where you're only placing one or two numerals.

Ideal applications: Precut numbers are well suited for sports leagues that limit teams to black or white uniforms. For white garments, you'll use black numbers, and colored garments will get white numbers (although they are available in various colors). This allows you to keep your inventory of precut numbers to a minimum.

Equipment and supplies: Basically all you need is a heat press, although it also helps to have a layout table. Consider setting up a 1/2-inch grid on the table to help align numbers on garments. You'll also want some cover sheets of Teflon or kraft paper. These prevent the heat press from touching the numbers. Also, heat tape will connect and keep letters and numbers in place.

CAD-Cut Numbers

Most popular materials: You can keep a few rolls of a variety of materials in stock, and you don't have to commit them to anything until an order is placed. This means you can provide fast turnaround for customers with last-minute requests, rather than waiting on precut numbers to arrive from a supplier.

Advantages: CAD-cut numbers allow for customization that you can't achieve with precut numbers, giving your customers many more choices in the look of their designs. Further, the spacing will be more accurate because you're creating the design on a computer.

Disadvantages: There's a higher investment than with precut numbers (namely the cost of the cutter itself).

Cost and labor comparison: CAD cutting isn't quite as cost-effective as precut numbers. The weeding process can be labor-intensive, although proper planning can help speed up the process. There also is some waste, as you do not use every square inch of the roll.

Ideal applications: CAD cutting is ideally suited for any customer who wants unique, customized lettering/numbering. You also may want to use the process in combination with another one; for instance, you could screen print the numbers but CAD cut the lettering.

Equipment and supplies: You'll need a heat press, a cutter (expect to spend anywhere from $1,000 to $1,700) and the material, which costs 1 to 2 cents per square inch. You'll also need weeding tools and cover sheets.

Print-and-Cut Numbers

Most popular materials: Print-and-cut is a process that uses one machine that inkjet prints numbers and letters in full color, then contour cuts them. Alternatively, you can use two machines — a printer, then a cutter. There's an enormous variety of materials available for this process. Use material that has a universal adhesive that will work on a wide variety of substrates, including nylon and leather. Materials come in lightweight and heavyweight variations. However, sturdy materials are popular because they're easier to weed, allowing for quicker application.

Advantages: This option provides considerable versatility, such as the fact that you can purchase white opaque material and print the colors you need; there's no need to stock a variety. You also can create between two- and four-color numbers without additional labor, and you can custom match colors to garments. Another advantage is that the finished garment has just one layer of film, making for a soft and pliable result regardless of the number of colors in the design.

Disadvantages: You'll spend more money on equipment initially, and production time is slower because it includes printing, cutting, weeding and masking. (However, printing and cutting happen unattended, meaning they don't require any labor.)

Cost and labor comparison: It's nearly as cost effective as CAD cutting for two colors, and it's actually more cost effective for three- and four-color designs. Overall, expect to spend about as much on labor as you would for CAD cutting.

Ideal applications: This option is perfect for jobs that require multiple colors, color matching, short runs or personalization. It also provides an extremely soft hand and excellent durability.

Equipment and supplies: You'll need a wide-format solvent inkjet printer/cutter or a printer and standalone cutter (look for one with an optical eye), heat press, masking tape, cover sheets, squeegees and weeding tools. A combo printer/cutter, like the Roland VersaCAMM, will cost between $11,000 and $16,000.

Transfer Numbers

Most popular materials: Suppliers offer numerous styles and colors of stock numbers screen printed onto transfer paper.

Advantages: Transfer numbers are easy to align because they're prespaced, and a grid on the back makes it easier to accurately space them and line them up. You can apply transfer numbers in just a few seconds, and double digits with multiple colors are already positioned on the paper.

Disadvantages: Transfer numbers aren't as durable as film, which holds up extremely well after multiple washes. Ink, on the other hand, may crack after numerous trips through the dryer. Also, you'll have to be careful not to press the numbers in reverse or upside down, especially with numbers like "8."

Cost and labor comparison: Transfer numbers are faster to apply than pre-cut numbers, but not quite as fast as CAD cutting. Average cost for 6-inch numbers are around 25 cents each, while 10-inch numbers cost about 45 cents each, making them less expensive than screen printing or CAD cutting. Labor is as simple as putting the transfer paper on the garment and heat pressing it for a few seconds, making it one of the easiest processes to use.

Ideal applications: Transfer numbers can be applied to cotton, polyester and cotton/polyester blends. They generally don't work well on nylon.

Equipment and supplies: You'll need a heat press and cover sheet.

Sewn Twill

Most popular materials: Suppliers offer a variety of twill styles, all of which you can purchase precut, or cut yourself and then sew down to the garment. (Some suppliers offer precut "no-sew" twill, which must be cut on a laser cutter so that the edges don't fray, as well as precut "faux stitch" twill.)

Advantages: Twill creates a crisp, professional, higher-end look that is worn by many college and professional athletes.

Disadvantages: You'll need to have the design digitized or purchase a pre-digitized disc.

Cost and labor comparison: Twill isn't that costly, but the process requires more steps, making it more expensive than other methods. However, its higher-end look allows you to charge more money.

Ideal applications: Twill is best suited for adult and elite leagues, as well as travel tournaments.

Equipment and supplies: Depending on which type of twill and design you use, you may need an embroidery or sewing machine, and digitizing software. You'll also need a heat press to flatten the numbers and give them a finished look.

Screen Printing

Most popular materials. Decorators can use regular plastisol or specialty inks on an enormous variety of garments. For instance, suppliers offer special inks made to minimize bleeding on polyester uniforms.

Advantages: There are advantages in using either dedicated inline numbering presses or stencils, says Bob Smothers, president, Sport Designs & Graphics, Effingham, Ill., whose shop has used both over the years. (Smothers estimates he prints more than 100,000 numbers a year.) Stencils are ideal for cost-conscious customers.

"Some people are trying to figure out how they're going to meet their budgets, and this is a way they can do it," Smothers says.

Also, labor costs are lower for stencil numbers than for screen printed numbers done on an inline machine, Smothers says. "You could do about 100 one-color numbers an hour with stencils and about 25 two-color numbers an hour on an inline machine," he says. Meanwhile, a dedicated numbering press provides speed and accuracy.

Disadvantages: There's more risk of spoilage in using any type of screen printing, especially when working with higher-priced garments. "You're buying a $20 jersey, and you have to replace it if you make a mistake," Smothers says. Also, for a dedicated numbering press, you'll need to have screens for each number, and each size and style of number — and they'll have to be re-stretched occasionally. "We have 65 numbering screens, all the way from 3-inch numbers to 12-inch numbers," he says. Further, it generally doesn't make financial sense to use screen printing for custom jobs.

Cost and labor comparison: "If you're testing your market, stencils are a fairly inexpensive way to go," Smothers says. "You can buy a set of one size of number stencils, numbers zero through nine, for about $125." On the other hand, while using a numbering machine requires a far more substantial upfront investment, it does provide for more speed and accuracy.

Ideal applications: While screen printing on a dedicated machine gives you more flexibility, stencils can be extremely cost-effective for the right kinds of jobs. "It might be a team that has at least numbers 1 through 10, and the order is for at least 100 shirts, and it's for only one-color numbers," Smothers says.

Equipment and supplies: Smothers has used inline machines for athletic numbering since 1996. "We have four in production," he says. "We spent more than $100,000 on those machines. You have to make the commitment to get the right equipment and resources if you're going to do team uniforms in volume."

Bob Robinson is a sales and education representative for Imprintables Warehouse. His production experience ranges from small custom orders to high-volume garment decorating for the past 12 years. For more information or to comment, e-mail bob@imprintableswarehouse.com or visit imprintableswarehouse.com.



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