BEHIND THE SCENES: HOW A CUSTOM JERSEY IS DESIGNED AND PRINTED

Ever wondered what happens between placing your order and receiving your custom jerseys? Here's a behind-the-scenes look at the complete journey of a jersey from concept to delivery at Athenax.

STEP 1: DESIGN CREATION

Our design team takes your requirements — team name, colors, style preferences, reference images — and creates a digital mockup in Adobe Illustrator. The design is crafted as a flat 2D panel layout at 23 inches by 31 inches at 300 DPI, ensuring every detail is print-perfect. This is the most critical step — the digital file is the blueprint for everything that follows.

STEP 2: CUSTOMER APPROVAL

We share the digital mockup showing front, back, and sleeve views. You review and request any changes — color adjustments, text corrections, logo repositioning. We iterate until you're completely satisfied. No jersey goes to print without explicit approval.

STEP 3: SUBLIMATION PRINTING

The approved design is printed onto special transfer paper using sublimation inks. The printed paper is then placed on the polyester fabric and fed through a heat press at approximately 200 degrees Celsius. Under heat and pressure, the ink converts to gas and permanently bonds with the polyester fibers. The result is a vibrant, full-color print that's literally part of the fabric.

STEP 4: CUTTING AND STITCHING

The printed fabric panels are precision-cut according to the size chart patterns. Experienced tailors stitch the panels together — front, back, sleeves, collar — using industrial overlock machines for strong, durable seams. Each jersey is individually assembled to the specified size.

STEP 5: QUALITY CHECK AND PACKING

Every finished jersey undergoes quality inspection — checking print alignment, color accuracy, stitching quality, size accuracy, and overall finish. Approved jerseys are individually packed and bundled for shipping.

STEP 6: DELIVERY

Orders are shipped via trusted courier partners with tracking. Most orders within India are delivered within 2-4 days of dispatch. The entire process from order confirmation to delivery typically takes 7-10 working days.

Ready to start your order? Browse our catalog and pick your design today.