What Is Dye Sublimation? - and How Does It Work?

If you’re wondering, “What is dye sublimation?” you’re more than likely interested in creating unique promotion items, such as printing on mugs, t-shirts, and more. Dye-sublimation printing allows for vivid, sharp, and vibrant imagery – and stunning products. 

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It’s also quite affordable if you aren’t planning on printing a large volume of products at a time. In fact, this form of printing is appreciated because it helps keep the budget low when producing a small number of items. Not to mention, dye sublimation creates considerably long-lasting prints, known for being extremely slow to fade.

This article goes beyond those quick answers to address what makes this form of printing special and how it expands what you can do. We comprehensively address this exciting technology via the following questions:

• What is Dye Sublimation?
• What is a Dye Sublimation Printer?
• What is Dye Sublimation Ink?
• What Materials Can Be Used in Dye Sublimation Printing?
• How Does a Dye Sublimation Printer Work?
• What are Different Types of Dye Sublimation Printers?

What is Dye Sublimation Printing?

Dye sublimation is a printing process using a specially designed ribbon that holds solid inks. The printer heats the ink, causing it to sublimate – which means it skips the liquid form and transitions directly into a gaseous state. (Another example of the use of sublimation within the industry is freeze-drying.)

Three primary colors are applied to the page or other material. Once the ink hits the media, it transitions from a gas back to solid, and a full-color image results. So that the ink does not smudge, the printer finishes by introducing a clear protective coating to the paper/substrate.

What is a Dye Sublimation Printer?

One way to understand a dye sublimation printer is to compare it to traditional inkjet printing. Here are three ways in which a dye sublimation machine differs from a standard inkjet printer’s process and capabilities:

1. Operation

    — The ribbon-heating gas generation process of a dye sublimation printer is described above. In contrast, an inkjet printer controls where ink droplets spray onto media from its cartridge’s nozzles. The cartridge is moved from side to side, producing a spectrum of color through the placement of these microscopic droplets. 

2. Efficiency

    — The efficiency of a dye sublimation printer is not as impressive as that of an inkjet printer. Within the former, the trio of primary color panels does not completely transfer onto the page — with the ink that remains on the panels will go to waste. The inkjet printer, on the other hand, will only use the required ink for a job.

3. Image Quality

    — Here, dye sublimation excels. Essentially, dye sublimation is similar to film, while inkjet printing is similar to video. The former creates an image similar to traditional photography, with a continually blended color range. A traditional inkjet printer is less seamless: you can see the primary color dots if the image is magnified. It is like an extremely detailed computer image.

What is Dye Sublimation Ink?

Dye sublimation ink is utilized, along with intense pressure and heat, to print onto novelty items such as coasters, t-shirts, plaques, and mugs. This form of ink has a few key benefits:

• It is longer-lasting than traditional inks. You will not see the image wash off or peel off of the printed item.

• Dye sublimation ink is water-proof.

• The high heat and coating make smudging nearly impossible.

• The accuracy is incredibly strong (given the specificity the vaporization allows over standard inkjet droplets).

What Materials Can Be Used in Dye Sublimation Printing?

These printers are not intended for typical workplace media such as printer paper, labels, or envelopes. Rather, they are popular for printing onto coffee mugs, t-shirts, and other novelty goods.

Substrates must be made of rubber, synthetic fabric, or plastic. This technology does not function correctly with cotton or other natural fabrics. Rather than bonding with natural fibers as it does with synthetic ones, gaseous ink passes straight through natural textiles.

Mouse pads, floor mats, coasters, flip-flops, event wristbands, bathing suits, shower curtains, and athletic apparel are examples of media containing the necessary materials suited to dye sublimation printing. Beyond these broad promotional uses, the machines can be used to create photo prints or postcards via specially coated media, such as cards or paper.

Dye Sublimation Printer Process: How Does it Work?

Again, what is dye sublimation? While the above information allows a better understanding of the basics, let’s get a bit deeper with the notion of transfer paper. Transfer paper is commonly used with these printers, although direct-to-fabric printing is also possible. If you use transfer printing, the process is a bit more complex.

When you use a dye-sublimation printer to create projects via transfer:

• The transfer paper will be outfitted with solidified ink. 

• A heat press is applied to the paper. 

• Sublimation occurs: the solid ink becomes a gas. 

• An incredible image starts to arise as the fibers of plastic material or synthetic fabric become permeated with the gas. 

It again helps to contrast a standard inkjet printer to a dye-sublimation printer (see above section). In the former, liquid ink within cartridges becomes solid via heat and air as it dries on the paper’s surface. The two-step dye sublimation printer process involves liquid ink being introduced to media, where it dries and becomes solid, followed by vaporization (sublimation, in this case) of the solid ink.

Example dye sublimation printing: cycling jerseys

Sublimated dye is often used to print onto cycling jerseys and similar athletic clothing. (As indicated above, this printer only works with synthetic substrates – so avoid cotton.)

Dye Sublimation Printing Process for Sportswear

What is dye sublimation printing for sportswear? Assuming you are using transfer printing, it is a four-step process:

Step #1. Create all the graphics.

You need to design graphics for each section of the jersey – the front and back, as well as the arms and cuffs. Combine the graphics into a master layout. The paper is printed from the master layout file.

Step #2. Print the dye sublimation ink onto the transfer paper.

You print the sublimation ink to a ream of transfer paper. The ink will rapidly form a solid.

Step #3. Utilize the roller for sublimation.

The transfer paper is positioned facing a bolt of synthetic fabric. The two items are directed into a sublimation roller.

Extreme heat (350-420 °F) and pressure are utilized within the roller to sublimate the ink. The ink that is on the transfer paper grows hot so fast that it skips the melting process and immediately evaporates. The vapor can also get deeper into the jersey because of the pores of the textile open in response to the heat.

The jersey’s pores shut once the heat is no longer present, capturing the sublimated ink. Within the jersey, the ink shifts back into a solid form. A permanent, full-color image has now been introduced to the fabric.

Step #4. Sew together the pieces.

At this point, you can throw out the transfer paper. Based on the parameters of your graphics, you should now have a bolt of fabric that includes all the components. Cut out each piece from the bolt and construct your finished jersey by sewing them together.

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Types of Dye Sublimation Printers

You have options when it comes to purchasing a dye-sublimation printer. Some of the most robust and versatile models are the following, with highlighted notable characteristics:

Fabric dye-sublimation printing lets you print onto many polyester textiles and coated surfaces, requiring specially manufactured inks containing heat-activated dyes. Once printed, textiles are heat-pressed or treated, and the backing paper is removed to give you a high-quality, finished print.

The beauty of fabric dye-sublimation is it is permanent; the ink won’t fade, flake or reduce in quality over time – ideal for high traffic areas.

This guide covers everything you need to know about fabric dye-sublimation printing so you can decide whether it is right for you.

Let’s jump in!

What is dye-sublimation printing?

Dye-sublimation printing involves using heat transfer ink to apply images to fabrics. The fabric is printed with a heat-activated dye/ink, and then it is heat-pressed or heat-treated, creating a permanent printed transfer.

Dye-sublimation printing with fabrics requires a dedicated printer, although some Inkjet printers can also do sublimation for papers.

Another version of dye-sublimation involves printing onto heat transfer paper and then heat-pressing the image onto the textile.

Pros & Cons of dye-sublimation printers

Dedicated dye-sublimation printers deliver better quality at an industrial scale, letting you print heat-transfer t-shirts, flags, banners, signs and fabric displays.

Here’s a rundown of the pros and cons:

Pros

• Durable and long-lasting
• Rapid print speeds
• Pre-configured material profiles
• A wide range of paper media and textiles supported
• Automated ink switching (industrial)
• Smooth feed system
• Production speeds in excess of 220sqm/hr (industrial)
• Jig systems for printing multiple items at the same time (industrial)
• Home printers cost as little as £400

Cons

• Relatively big, so printers take up floor space (industrial)
• More steps in the process
• Industrial printers are expensive, typically over £20k for an introductory model

As we can see, the pros outweigh the cons, and the only downsides are the size of the printers and the cost. However, they are considered capital equipment, and you can often lease the equipment rather than buy it outright.

What materials can you print with dye-sublimation printing?

Dye-sublimation printing is most suitable for printing on polyester textiles, including flags, banners, displays and signs. It can also be used on nylon pre-treated with additives to improve dye absorption.

Polyester is best because when heated, the polyester melts slightly, bonding with the dyes to create a permanent image transfer.

Business opportunities with dye-sublimation printing

Dye-sublimation printing produces extremely high-quality images that are worthy of the finest t-shirts and banners. As a printing company, you can sell a wider range of products that cater for customers wanting the best.

Additionally, dye-sublimation printers capture astonishing detail, creating an accurate physical representation of any digital design. This unlocks new design opportunities, letting you create personalised products.

Here are a few of the business opportunities:

• Banners: Polyester and PVC banners are suitable for dye-sublimation printing, and you can print images of any size, depending on the printer you have. Fabric banners can have permanent images that are UV-resistant and suitable for any application.
• Soft signage: Soft signage is another great use case for dry-sublimation printing, letting you print on flags, notices and displays.
• Backlit signage: Dye-sublimation printing is suitable for backlit displays printed on polyester, creating a high-quality image.
• Interior décor: Customers who buy signs and banners might also buy interior décors like fabric posters, notices and advertisements.

Overall, dye-sublimation unlocks enormous opportunities for commercial printers.

Difference between “direct” & “transfer” dye-sublimation printing

There are two types of dye-sublimation printing:

• Direct: Involves printing directly onto the fabric/textile
• Transfer: Involves printing onto transfer paper applied to the fabric/textile

Both of these have different use cases. Direct printing is better for large print runs, sizeable banners and signs, while transfer printing is better for smaller products.

Additionally, there are direct and transfer printers. Some printers only do transfer dye-sublimation printing, only supporting paper media, and other printers support paper media and textile media, giving you both options.

What do I need for dye-sublimation?

To make dry-sublimation printing possible, you need the following:

• Sublimation printer
• Sublimation paper for transfer (or textile for direct)
• RIP software to create files the printer can understand
• Heat press
• Cutting mechanisms, such as a rotary blade or a guillotine

Why choose dye-sublimation?

Dye-sublimation creates beautiful, high-quality graphics and images that are an accurate physical representation of the original designs. The dye is embedded in the fabric, making it permanent and suitable for indoor and outdoor use.

The longevity of products printed with dye-sublimation is legendary, with the images never fading, peeling, flaking or degrading. UV-resistant dyes can be specified to extend the life of the image further if used outdoors.

However, while dye-sublimation works great with polyester, PVC and nylon are harder to print due to dye bonding problems. You can solve this issue by using PVC and nylon designed for heat transfer inks.

Is sublimation worth the investment?

Yes! Demand for printed textiles is soaring, and dye-sublimation yields the best overall product quality. It also lets you create a wider range of products, from banners and soft signage to backlit signs, clothes and fabric apparel.

Commercial printers can use industrial-size textile printers for dye-sublimation. In contrast, smaller businesses and home businesses can use an Inkjet desktop printer designed for dye-sublimation for heat transfer printing.

Like any print process, dye-sublimation has pros and cons. But if you want to print high-res, permanent images on textiles, nothing else comes close.

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