Puff Print (Raised Ink) for Hoodies and Tees
- 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 puff print is
Puff print is a screen-printing technique in which a puff (blowing) additive is mixed into the ink before printing; when the printed ink is cured, the additive expands and lifts the design off the fabric to give a raised, three-dimensional effect. The result is a soft, matte, slightly rounded surface rather than the flat ink layer of a standard screen print.
Puff is a finish, not a separate machine. It runs on the same flatbed screen-printing line we use for flat plastisol prints, so it can share a garment with flat colour, embroidery or DTF in the same order. Each colour of puff still needs its own screen.
The technique is associated with streetwear-style hoodies and sweatshirts, where a raised wordmark or logo on 280–350 GSM fleece reads as a heavier, more tactile finish than a flat print. ZipaSports in Sialkot, Pakistan prints puff for startup apparel brands, gym merchandise, dance and cheer warm-ups, and club leisurewear.
How puff ink is applied, step by step
Puff ink follows the normal screen-printing sequence with two differences: a heavier ink deposit and a cure stage that has to reach the additive's expansion temperature without over-heating the fabric.
| Stage | What happens | Effect on the finished print |
|---|---|---|
| 1. Ink preparation | Puff additive is mixed into plastisol ink at a set ratio | More additive gives more rise; too much weakens the ink film |
| 2. Screen preparation | A coarser mesh and thicker stencil are used than for a flat print | A heavier ink deposit is what allows a visible lift |
| 3. Print | Ink is pushed through the screen onto the garment panel | Edges should be clean; the ink spreads slightly as it rises |
| 4. Flash and cure | The print is heated until the additive expands and the ink fully cures | Under-curing causes cracking; over-heating flattens or scorches the puff |
| 5. Cool and check | Pieces cool flat before handling; first pieces are checked for rise, cure and registration | In-line QC before the run continues |
Because the rise happens in the cure stage, the height of the finished print is set by additive ratio, ink deposit and cure temperature together. We fix these on the first pieces of each run rather than per garment, so every hoodie in the order carries the same lift.
Fabrics that take puff print well
Puff print performs on stable, medium-to-heavy fabrics, which is why it is most often used on fleece and cotton tees rather than on thin polyester jerseys or stretch knits. The raised ink needs a base that will not distort around it.
| Fabric | Puff suitability | Notes |
|---|---|---|
| Cotton-polyester fleece, 280–350 GSM | Good | The standard puff base for hoodies, sweatshirts and joggers; smooth face side gives an even rise |
| 100% cotton tee fabric | Good | Bold wordmarks and logos; keep total print area moderate so the tee still drapes |
| Performance polyester fleece, 240–300 GSM | Good with care | Cure temperature is kept lower to avoid dye migration into the light ink |
| Polyester or poly-cotton piqué | Fair | The textured surface gives a slightly uneven rise; small logos only |
| Polyester interlock jersey, 140–180 GSM | Limited | A raised print feels stiff against a light knit; sublimation is the better option for jerseys |
| Nylon-spandex and polyester-spandex, 240–300 GSM | Not recommended | 4-way stretch pulls the raised ink apart at the edges |
On dark fleece, a white or pale puff wordmark gives the highest contrast; on light fabric, a dark puff logo shows its shadow line more clearly. Both are shown on the free mockup within 24 hours before screens are made.
Design rules for puff print
Puff print favours bold, simple shapes because the ink spreads and rounds as it rises, so fine detail closes up and very thin lines disappear. Design for puff the way you would design for a rubber stamp, not for a photograph.
| Do | Avoid | Why |
|---|---|---|
| Bold wordmarks, block letters, solid shapes | Fine lines, hairline outlines, script with thin strokes | Thin ink deposits do not carry enough additive to rise, and thin strokes break |
| Generous spacing between letters and elements | Tight kerning, small counters (the holes in a, e, o) | The ink spreads outward as it puffs and fills tight gaps |
| Flat spot colours, one or two per design | Halftones, gradients, photographic artwork | Dots and fades need fine detail that puff cannot hold |
| Moderate print areas: chest logos, wordmarks | Huge solid blocks across the full front | A large raised slab stiffens the garment and can crack at fold lines |
| Rounded or slightly softened corners | Razor-sharp corners and serifs | Corners round off naturally when the ink rises |
| Puff for the hero element, flat ink for detail | Making every element puff | Contrast between raised and flat is what makes the effect read |
Send vector artwork and Pantone references; the free design service can thicken strokes and open up counters to make a flat logo puff-ready before you approve the mockup.
Durability and wash care
A fully cured puff print is as wash-durable as a standard plastisol screen print: it does not wash off, and it keeps its rise through normal domestic laundering when the garment is washed inside out and kept away from direct heat. The two things that shorten a puff print's life are under-curing at the factory and high heat at home.
| Care action | Recommendation | Why |
|---|---|---|
| Washing | Inside out, cold or warm cycle | Reduces abrasion on the raised surface |
| Bleach | Do not use | Attacks the ink pigment and the fleece |
| Drying | Line dry or low tumble | High heat can flatten or re-soften the puff |
| Ironing | Never iron directly over the print; iron inside out if needed | Direct heat and pressure crush the rise permanently |
| Dry cleaning | Do not dry clean | Solvents can affect plastisol ink |
At the factory end, the QC team checks the first pieces off each run for full cure and consistent rise before the run continues, and repeats the check at final QC. A cracked, peeling or unevenly puffed print counts as a manufacturing defect, and the free remake policy for defects is set out in the ordering section below. These care rules can be printed on your own care labels for private-label orders.
Combining puff with flat screen print and other methods
Puff print gives the strongest result when it is combined with flat ink or another method rather than used alone, because the contrast between raised and flat elements is what makes the effect read. The combinations below all run in-house at ZipaSports on the same garment.
- Puff plus flat screen print. The wordmark or main shape is printed in puff while an outline, tagline or fine detail is printed in flat plastisol from a second screen. Registration between the two screens is checked on the first pieces.
- Puff outline, flat fill. A raised border around a flat-printed logo keeps the detail crisp while still giving a tactile edge.
- Puff plus embroidery. A club crest is embroidered on the chest and a puff wordmark goes across the back, a common pairing on club and academy hoodies.
- Puff plus DTF. Full-colour sponsor logos or photographic artwork are applied by DTF while the brand name is puffed, useful when the artwork mixes gradients with a bold mark.
When combining methods, the puff element is normally printed and cured first so that the raised surface is not crushed by a later press or embroidery hoop, and the sequence is confirmed on the physical sample.
Garments and buyers for puff print
Puff print is most often ordered on fleece hoodies, crewneck sweatshirts, joggers and heavyweight cotton tees, which are the garments where a raised finish suits the fabric weight and the way the piece is worn. We manufacture all of these in Sialkot, Pakistan and apply the puff in-house.
- Hoodies and jackets: pullover and zip hoodies in 280–350 GSM cotton-polyester fleece with a puff chest logo or back wordmark, ordered by activewear brands, gyms and CrossFit boxes as member merchandise.
- Dance and cheer tops, jackets and warm-ups: studio names and team wordmarks in puff on warm-up hoodies and crewnecks, often paired with rhinestone or embroidered crests.
- Gym tops and heavyweight tees: bold puff wordmarks on cotton or cotton-rich tees for gym and studio merchandise.
- Club and academy leisurewear: sports clubs, universities and football or martial-arts academies ordering off-pitch hoodies to match sublimated playing kit.
- Joggers and tracksuit bottoms: small puff logos on the hip or thigh, kept small so the print does not stiffen the leg.
Distributors and teamwear resellers can order puff-print garments under their own labels with woven neck labels, printed size tags, hang tags and branded polybags supplied in-house.
Ordering puff-print hoodies and tees from ZipaSports
ZipaSports manufactures and puff-prints hoodies, sweatshirts, joggers and tees in-house in Sialkot, Pakistan, with a minimum of 20–25 pieces per design, lower quantities on request, and no MOQ limit for sportswear brands and companies. Send your logo, sketch or idea and the studio returns a free digital mockup within 24 hours, with unlimited free revisions before approval.
- Physical sample: 5–7 days, charged at sample cost and credited against your bulk order;
- Bulk production: 15–25 business days after design approval; express production in 7–12 days at additional cost.
- Shipping: DHL, FedEx or UPS air freight in 5–10 days worldwide; sea freight in 3–6 weeks for bulk.
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. For puff print, a cracked, peeling, unevenly raised or mis-registered print counts as a defect. Send photos and your order reference on WhatsApp or email within 7 days of delivery; we confirm within 24 hours during business hours and ship the replacement pieces at no charge.
Pricing depends on fabric, quantity and the number of print colours and positions; contact us on WhatsApp for a quote within 24 hours. See also screen printing and the printing and decoration hub.
Frequently Asked Questions
What is puff print?
Puff print is screen printing with a puff additive mixed into the ink; when the printed ink is cured, the additive expands and lifts the design off the fabric to give a raised, matte, three-dimensional finish. It is most often used for wordmarks and logos on fleece hoodies, sweatshirts and heavyweight cotton tees.
Does puff print work on polyester?
Puff print works on polyester fleece and piqué when the cure temperature is kept low enough to avoid dye migration, but it is not recommended on thin polyester jerseys or 4-way stretch knits. On 140–180 GSM polyester interlock the raised ink feels stiff against the fabric, and on nylon-spandex or polyester-spandex the stretch pulls the print apart at the edges.
Does puff print crack or peel?
A fully cured puff print does not crack or peel in normal washing. Cracking almost always comes from under-curing, which is why we check the first pieces of each run for full cure and rise before continuing. At home, avoid hot tumble drying and never iron directly over the print, because heat and pressure flatten the puff.
Can puff print reproduce fine lines or small text?
No, puff print cannot reproduce fine lines or small text, because the ink spreads and rounds as it rises, so hairline strokes disappear, tight letter spacing fills in, and halftones or gradients cannot be held. Design puff elements as bold shapes and block lettering with open counters, and put any fine detail in flat screen print, DTF or embroidery on the same garment.
How do I wash a puff-print hoodie?
Wash a puff-print hoodie inside out on a cold or warm cycle, do not use bleach, line dry or tumble on low, and never iron directly over the print. Dry cleaning is not recommended because solvents can affect plastisol ink. These care instructions can be printed on the size tag or care label of private-label orders.
Can puff print be combined with regular screen print?
Yes, puff print can be combined with regular screen print on the same garment: the main shape or wordmark is printed in puff ink from one screen and the outline, tagline or fine detail is printed in flat plastisol from a second screen. We also pair puff with embroidery and DTF on the same hoodie, with the puff element normally printed and cured first.
How many colours can a puff print have?
Each puff colour needs its own screen, so most puff designs use one or two colours, with any extra detail printed in flat ink. Because the raised surface is the feature, a single-colour puff wordmark on a contrasting fleece usually reads more strongly than a multi-colour puff design.
What is the minimum order for puff-print hoodies?
The minimum order at ZipaSports is 20–25 pieces per design, with lower quantities possible on request for sample runs and small teams, and no MOQ limit for sportswear brands and companies. Screens are made per design, so ordering all sizes of one design in a single run is the most efficient approach.
Puff print or embroidery for a hoodie logo?
Choose embroidery for a small crest or logo that should look stitched and last the longest; choose puff print for a large wordmark or bold shape where a soft raised surface is wanted without the stiffness of a large embroidered area. Many club and brand hoodies use both: an embroidered chest crest and a puff back print.
How long does a puff-print order take?
You receive a free digital mockup within 24 hours, a physical sample in 5–7 days if requested, and bulk production takes 15–25 business days after design approval, with express production in 7–12 days at additional cost. Air freight from Sialkot, Pakistan by DHL, FedEx or UPS takes 5–10 days worldwide.