Polyester Interlock Fabric for Sportswear
- Est. 2005 · Sialkot, Pakistan
- MOQ 20–25 pcs per design · no limit for brands
- Free 24h digital mockup
- Sample 5–7 days, credited on bulk
- Bulk 15–25 business days · express 7–12
- DHL/FedEx/UPS 5–10 days
- 🛡️ Free remake within 3 days
What polyester interlock is
Polyester interlock is a double-knit fabric made on a machine with two needle beds, so both faces of the cloth show the same smooth, flat stitch. Single jersey, the common T-shirt knit, has a smooth face and a looped back and curls at cut edges; interlock lies flat, is thicker for the same yarn, and recovers its shape after stretching without the bagging that single jersey shows at the elbows and hem.
For sportswear ZipaSports uses interlock knitted from 100% polyester yarn at 140–180 GSM, with a moisture-wicking finish applied at the mill. Polyester is used rather than cotton for two reasons: the fibre absorbs almost no water, so sweat moves to the surface instead of soaking in, and the dye-sublimation process only bonds to polyester.
The result is the closed-face jersey fabric used for most club football, cricket, basketball and esports kits. It has moderate two-way stretch from the knit structure itself, with no elastane, which keeps the cloth stable during printing, cutting and sewing.
Why interlock is the standard base for sublimation
Interlock takes dye-sublimation cleanly because its face is closed: there are no holes, so the sublimated image has a continuous surface to bond to. Fine sponsor text, thin pinstripes, gradients and photographic panels all reproduce with clean edges, which is not the case on open mesh, where the design breaks up across the holes.
In the dye-sublimation process the design is printed in reverse onto transfer paper, then paper and fabric pass through a heated calender at around 200 °C. The dye turns to gas and bonds inside the polyester fibre, so the print is part of the cloth: it does not fade, crack or peel, and it adds no weight or stiffness to the garment.
Because the base cloth is white, every colour in a design starts from white and any colourway is possible without dye lots or screens per colour. A twelve-colour jersey takes no more print set-up than a two-colour one. Panels are printed before cutting, so the colour runs edge to edge into every seam, collar and side panel.
Moisture-wicking finish: what it does on the pitch
The moisture-wicking finish on polyester interlock spreads sweat across the outer face of the fabric so it evaporates faster than it would on untreated polyester. Polyester fibre itself absorbs very little water compared with cotton, so sweat sits on the fibre surface and travels along the channels between yarns by capillary action; the finish improves that spreading so the wet patch dries quickly instead of forming a dark ring.
In practice a wicking interlock jersey stays lighter and does not cling during a match, while a cotton shirt of the same weight holds sweat against the skin. The finish is applied at the mill, before printing, and survives sublimation and normal domestic washing.
The finish is a treatment, not a fibre, so specification sheets read "100% polyester interlock, moisture-wicking finish, 140–180 GSM" rather than naming a branded wicking yarn. Wash-fastness and colour-fastness checks are run on the sublimated interlock, so the finish and the print are both confirmed on the actual production cloth.
Garments made in polyester interlock
Interlock is the default fabric for any sublimated top or short where print detail matters more than maximum airflow. The table lists the standard uses and the part of the 140–180 GSM range usually proposed for each.
| Garment | Usual GSM | Why interlock | Discipline page |
|---|---|---|---|
| Football jerseys | 150–170 | Sharp sponsor logos and pinstripes; holds shape over a season | Football kits |
| Cricket shirts (coloured T20 kit and whites) | 160–180 | Opaque enough for white kit; smooth face for full-colour designs | Cricket kits |
| Basketball jerseys and shorts | 150–170, often paired with mesh | Clean numbering and side-panel prints; mesh used where airflow matters | Basketball uniforms |
| Esports jerseys | 160–180 | Photographic sponsor walls and gradients need a closed print face | Esports jerseys |
| Training tees and warm-up tops | 140–160 | Light and quick-drying at the light end of the range | Training wear |
| Team shorts | 140–180, interlock or microfibre | Matches the jersey print exactly; no colour break at the waistband | Match shorts |
All of these are cut on computer-controlled cutters after printing, sewn on overlock and coverstitch lines, and finished with the buyer's own woven neck label and printed size tag.
Interlock vs mesh vs piqué
Interlock, mesh and piqué are the three knits used for sublimated team tops, and the choice comes down to print detail against airflow against collar structure.
| Property | Polyester interlock | Polyester mesh / pin-dot mesh | Polyester piqué |
|---|---|---|---|
| Knit structure | Double-knit, closed smooth face on both sides | Knit with regular holes; pin-dot has very small holes | Textured waffle face, closed |
| GSM range | 140–180 | 140–180; open-hole motocross mesh 150–180 | 160–200 polyester; 200–240 poly-cotton |
| Airflow | Moderate, by wicking and evaporation | Highest; holes pass air directly | Moderate |
| Sublimation detail | Highest detail: fine text, gradients, photos | Good on pin-dot, reduced on open mesh | Good; the texture softens very fine lines |
| Opacity | High, suitable for white kit | Lower; mesh shows skin or an undershirt | High |
| Shape retention | High; flat edges, no curl | Moderate | High; holds a collar and placket |
| Typical garments | Football, cricket, esports jerseys; shorts | Basketball jerseys, hot-climate football, motocross | Polos, pit shirts, cricket collars |
Many kits combine two of these: an interlock body with mesh underarm or side panels, or an interlock cricket shirt with a piqué collar. Because all three are 100% polyester they sublimate in the same run and colours match across panels.
Choosing the GSM: climate, season and use
Within the 140–180 GSM range the right weight depends on where and when the kit is worn, not on a quality scale: heavier is not better, it is warmer and more opaque.
| GSM | Feel | Suits | Notes |
|---|---|---|---|
| 140–150 | Very light, slightly translucent in pale colours | Summer training tees; hot-climate leagues in the GCC, South Asia and the Australian summer | Choose darker colours, or add mesh panels, if opacity matters |
| 155–165 | Standard match weight | UK, European and North American season play; cricket coloured kit; esports | The usual starting point proposed for club football jerseys |
| 170–180 | Fuller hand, fully opaque | White cricket kit; winter fixtures; long-sleeve jerseys; retail replica shirts | Highest opacity for pale colourways; slightly warmer to wear |
Clubs that play year-round often order the same design at two weights: 150 GSM short-sleeve for summer and 170 GSM long-sleeve for winter, printed from the same artwork so both look identical. See the football jersey GSM guide for a longer walkthrough, or send the fixture climate and the studio will propose a weight with your mockup.
Who orders interlock jerseys from ZipaSports
Interlock jerseys are ordered from ZipaSports in Sialkot, Pakistan, by five main buyer groups, and the same fabric serves all of them at different quantities.
- Sports clubs and teams: Sunday league, university and corporate sides ordering a home and away kit from 20–25 pieces per design, usually with player names, numbers and a sponsor logo sublimated in.
- Academies and schools: football and cricket academies ordering training tees and match kit across youth and adult size charts, often repeated at each intake.
- Sportswear brands: startup and established labels ordering private-label jerseys with their own woven neck labels, size tags and packaging; there is no MOQ limit for sportswear brands and companies.
- Distributors and teamwear resellers: kit suppliers who sell interlock kits under their own catalogue and need the same GSM and colour from one order to the next.
- Esports organisations and event organisers: tournament and team jerseys where sponsor walls and photographic panels need the closed interlock face.
Every order starts with a free digital mockup within 24 hours. A physical sample takes 5–7 days, is charged at sample cost, and that cost is credited against the bulk order. Bulk production runs 15–25 business days after design approval, with express production in 7–12 days at additional cost.
Care instructions for sublimated interlock
Sublimated polyester interlock needs no special care because the colour is inside the fibre, not on the surface; the instructions below protect the fabric and the wicking finish rather than the print.
- Machine wash cold or at 30 °C, inside out, with similar colours. Hot washes can set stains and stress the wicking finish.
- Use a normal detergent. Do not use fabric softener: it coats polyester fibre and reduces wicking.
- Do not bleach. Chlorine will not remove the sublimated colour, but it weakens the fibre and any heat-applied numbers.
- Line dry or tumble dry on low. Polyester dries quickly, and high dryer heat can set creases into the knit.
- Iron on a low synthetic setting only if needed, through a cloth. Never iron directly over heat-transfer vinyl numbers or DTF logos where a kit combines methods.
- Wash muddy kit promptly; polyester holds odour if left damp in a bag.
These instructions are printed on the size tag or a separate care label as part of the private-label labelling service, so the end wearer sees them on every garment.
Frequently Asked Questions
Is polyester interlock good for football jerseys?
Polyester interlock at 150–170 GSM is the standard fabric for sublimated football jerseys. Its closed double-knit face prints sponsor logos and stripes sharply, holds its shape over a season and wicks sweat. Hot-climate teams often add mesh side panels for extra airflow.
What GSM should a polyester interlock jersey be?
A polyester interlock jersey should be between 140 and 180 GSM. ZipaSports proposes 140–150 GSM for summer training tees and hot climates, 155–165 GSM for standard match kit, and 170–180 GSM for white cricket kit, winter fixtures and long-sleeve jerseys where opacity and warmth matter more than lightness.
Does sublimated interlock fade, crack or peel?
Sublimated polyester interlock does not fade, crack or peel. Dye-sublimation turns the dye to gas at around 200 °C and bonds it inside the polyester fibre, so there is no ink layer on the surface to crack or peel and the colour does not wash out. Wash-fastness and colour-fastness checks are run on the sublimated cloth.
What is the difference between interlock and single jersey?
Interlock is a double-knit with two smooth faces and flat cut edges; single jersey is a single-bed knit with a looped back that curls at the edges. Interlock is thicker and more stable for the same yarn, which is why it is preferred for sublimated team kit.
Is interlock breathable enough for hot climates?
Polyester interlock at 140–150 GSM is light enough for hot climates, although it moves less air than mesh. A wicking interlock at that weight dries fast and feels light. For GCC, South Asian or Australian summer leagues the studio usually suggests interlock front and back panels with pin-dot mesh sides or underarms.
Can polyester interlock be embroidered or screen printed?
Polyester interlock can be embroidered, screen printed or decorated with DTF as well as sublimated. Its stable double-knit face takes embroidery for crests and screen printing or DTF for single-colour logos. Most buyers still sublimate the whole garment and add an embroidered crest only where a raised badge is wanted, since sublimation already covers unlimited colours.
Does polyester interlock shrink?
Polyester interlock does not shrink in normal domestic washing at 30 °C because the fibre is dimensionally stable. Because panels are sublimated under heat before cutting, any relaxation happens before the garment is measured, and finished pieces are checked against the approved size specification within a ±1–1.5 cm tolerance.
Can I get interlock in recycled polyester?
GRS-certified recycled polyester interlock is available from ZipaSports on request in the same 140–180 GSM range and prints identically with sublimation. Confirm it at enquiry stage so the correct yarn is sourced before sampling; certificate copies are available on request.
What is the minimum order for interlock jerseys?
The minimum order for interlock jerseys is 20–25 pieces per design, lower on request, with no MOQ limit for sportswear brands. A club can therefore order a first kit for one squad, and a brand can order any quantity once established. Every order includes a free digital mockup within 24 hours before anything is cut.
What happens if an interlock jersey arrives with a defect?
Quality Guarantee: if any garment arrives with a manufacturing defect, we remake it free of charge — the remake goes into production within 3 days of your report. Send photos and your order reference on WhatsApp or email within 7 days of delivery; we confirm within 24 hours and ship replacements at no charge.