When you open your wardrobe, have you ever noticed that some prints on T-shirts are stiff and rough while others are very smooth as if a natural part of the fabric? Sublimation printing is one of the most commonly used methods to create a pattern getting all cozy with the fabric.
In this blog, we’re pulling back the curtain on the magic trick of sublimation printing, revealing how it works, its advantages and disadvantages, and where it’s commonly used.
What Is Sublimation Printing?
Sublimation printing, also known as dye-sublimation printing or thermal sublimation printing, is a specialized method for printing precise and permanent patterns on various materials. Built upon digital printing technologies and the principles of sublimation, it emerged as a modern and advanced technique.
As you may know, the term “sublimation” refers to a physical process where a solid substance turns directly into a gas one directly, bypassing the liquid state. Sublimation printing got its name because it was believed that its inks undergo a direct solid-to-gas transformation. However, in reality, part of the ink turns into liquid during the process.
Types of Sublimation Printing
Sublimation printing mainly comes in two types, sublimation transfer printing and direct dye sublimation. These two methods both utilize specialized inks that change state, penetrate, and merge with the substrate to be printed.
However, sublimation transfer printing resorts to a paper or film designed to retain the design’s definition and vividness as a transfer medium. In contrast, direct dye sublimation prints patterns directly onto materials.
How does Sublimation Printing Work?
The process of sublimation printing is like a magic trick where inks get a new lease on life, reborn within materials, and giving them a fresh, vibrant appearance.
Sublimation transfer printing starts by printing on the transfer papers or films with technical water-based disperse inks. The patterns are first transferred onto specialized paper or film coated with adhesive organics, as mirrored images. Then these printed papers or films get fed into a pressing machine where heavy pressure and high temperatures (at around 400 to 450 degrees Fahrenheit) are applied.
After about 10 seconds, the specialized inks and coatings on the papers or films work together to transfer the printed patterns directly onto the materials of choice. While the heat cranks up, the inks leave the transfer media as gas and a small amount of liquid, infiltrating opened pores of fibers or other substrates and becoming an integral part after cooling. Thus, instead of just sitting on top with rough patches, sublimation prints are embedded into objects.
Directly dye sublimation skips the resort of transferring sheet, bringing the substrates directly into contact with the inks during sublimation. Subsequently, the printed patterns should be cured by high heat. This printing process generally has better ink penetration, inks able to reach the reverse side.
Pros and Cons of Sublimation Printing
As one of the most popular printing methods, sublimation printing still has promises and perils. The main upsides of this involve:
- Huge freedom in designs and patterns: sublimation printing allows endless creativity and possibilities, from intricate artwork to photographic images.
- Vivid renditions in multiple colors: This method brings a complex level of detail and can print a pattern in a variety of colors.
- Superior durability and ease of maintenance: Sublimation prints won’t easily fade, crack, flack, or peel, and they are completely washable.
- Future prospective: As a technologically progressive method, sublimation printing has great potential for improvement in the future.
- Cost-effectiveness: Dye sublimation produces high-quality printing effects with relatively budget-friendly prices, especially for small runs. It also contains no setup fees.
- Low impact on the environment: Sublimation printing has minimal ink waste due to its usage of digital technologies and sublimation reactions. Besides, its process requires very little water.
For all its good sides, there are still some drawbacks.
- Limitations on hues: Sublimation printing only prints hues that can be represented digitally, though numerous colors it can achieve.
- Limitations on substrates: Sublimation printing is not feasible on all materials and imposes some restrictions on material content and color.
- High demand for expertise knowledge and technicians: As a technological printing method, dye-sub printing requires a strong command of specialized knowledge and skills. Without this expertise, flaws like colored creases can ruin the materials.
What Is Sublimation Printing Used for?
Dye-sub printing excels at producing vibrant designs on white or light-colored materials, especially when patterns rely on detailed and colorful brush strokes. Moreover, it is a viable option for customization.
Sublimation Printing on Textiles
Sublimation printing is particularly suitable for synthetic fabrics, especially polyester and blends of high poly content. These fabrics possess rich fibral pores that can open up under specific conditions, allowing inks to slip in and settle down.
This technique is widely used in garments and accessories, including sportswear, T-shirts, bandanas, scarves, and more. It is often well-suited for home décor products, such as cushion covers, pillowcases, table covers, curtains, and more. Some items for promoting or marketing, like banners, signs, and flags, are also in dye-sub prints.
Sublimation Printing on Other Materials
Sublimation can be used for page printing, despite less frequent usage. It is used in medical imaging, ID cards, instant photos, postcards, and more.
It is also effective on any surface coated with poly, as well as some hard materials, such as wood, metal, glass, ceramics, and more. Everyday objects, including pens, tins, clocks, and more, often feature sublimation-printed designs.
Sublimation Printing VS Heat Transfer Printing
Many conflate sublimation printing with heat transfer printing, or confuse the two. While sublimation printing and heat transfer printing share some similarities in processing, their outcomes differ significantly.
- Color and printing effects: Sublimation printing offers a broader range of color options and bounds prints with substrates into an entirety while heat transfer printing deposits patches of patterns on the surfaces.
- Cost: Sublimation printing uses more expensive inks and requires higher temperatures (higher energy fee). Heat transfer printing, on the other hand, is less expensive, as it uses cheaper materials and does not require as much energy.
- Comfort: Garments produced with sublimation printing are more breathable and comfortable since the prints become part of the fabric. Instead, heat transfer printed ones feel stiff and stuffy.
- Durability: Sublimation prints are long-lasting and resistant to wear and tear while heat transfer prints tend to be less durable, and prone to discolor, crack, and peel.
Sublimation Printing VS Screen Printing
- Applicable designs: Dye-sub printing does not have restrictions on designs whereas screen printing is ideal for simple patterns like graphics, and produces special effects like flocking and three dimensions.
- Applicable colors: Dye-sub printing can print any color able to be created on digital images, even in one run. Screen printing can print any visual color, but is better suited for a small number in the same run.
- Setup costs: Sublimation printing charges less in the beginning. Screen printing requires a more substantial setup, including the creation of screens for each color.
- Order sizes: Sublimation printing is suitable for small orders but can take longer for bulk production. Screen printing, while cost-prohibitive for small runs, is highly cost-efficient and time-saving for large orders.
FAQs
What Is Sublimation Printing on Shirts?
Sublimation printing on shirts is one of the most common applications of this printing method. It comes in several types:
- Direct-to-garment sublimation transfer printing
- Direct-to-garment sublimation direct printing
- Roll-to-roll sublimation transfer printing
- Roll-to-roll sublimation direct printing
The latter two methods are applied on fabrics, before cutting and sewing of shirts.
Can Sublimation Print White?
No, it can’t. Sublimation printing typically uses the CMYK color mode, where colors can’t be combined to create white color. Consequently, any area of the design intended to be white will simply take on the color of the substrate. For example, if you print on a blue shirt, the parts of the design that should be white will appear blue. To truly achieve white in your design, you would need to print on a white shirt.
To address this issue, sublimation printing can be combined with HTV printing (Heat Transfer Vinyl). By using HTV for the white sections and sublimation for the rest, you can create final product with a precise match in color.
How to Print Sublimation Images？
For home DIY, create or select a design and get a digital file from it first, e mirrored before printing. Next, set up a sublimation printer with the appropriate inks and transfer paper. Third, print the design onto the transfer paper. Then, prepare the substrate, laying fat, spotting area to be printed, and attaching a heat-safe tape. After that, preheat the press to about 400°F, and press the transfer paper face down for 30 to 60 seconds, with a butcher paper protecting the press. Finally, remove the paper to reveal the embedded image.
Why Are My Sublimation Prints Dull？
Dull sublimation prints can result from several factors, including improper transfer paper or ink, wrong temperature or time, and unsuitable substrates.
How Long Does A Sublimation Print Last?
Sublimation prints are highly durable and can be permanent with proper maintenance, precisely of the same lifespan as its substrate. Proper care involves washing the print in cold water and avoiding harsh detergents. Further, for sublimation prints on a garment, clean it with the inside out.
Conclusion
Now you’ve gained insight into sublimation printing and some extra tips for choosing clothes, accessories, and daily items. Sinosilk is a trusted supplier of premium polyester fabrics and poly-based products, expertly printed using sublimation transfer technology. Join us in exploring the exquisite craftsmanship and precision of this technique, and unlock the full potential of your business.
More Resources
What is screen printing? – Source: Sinosilk
What is reactive printing? – Source: Sinosilk
14 Types of Textile Printing and How They Print on Fabrics – Source: Sinosilk