What Is Sublimation Printing? Your Comprehensive Guide Explained

Sublimation printing guide

Sublimation printing is a versatile printing method for adding vivid, full-color designs to a wide range of products. From clothing and accessories to woods and ceramics, sublimation printing has revolutionized the art of customizing everyday items with eye-catching graphics

In this article, we’ll delve into the nitty-gritty. We’ll explore how it works, what products it can transform, pros and cons and how it compares to other printing methods. 

Ready to dive deep into the world of sublimation?

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What is sublimation printing, and how does it work?

The process of sublimation printing allows the transfer of full-color, high-resolution images onto a variety of man-made surfaces using a combination of heat and pressure. The technique involves the transformation of special sublimation inks, known as disperse dye sublimation, into a gaseous state at high temperature. 

How to print sublimation images? A CMYK ink-mix is first printed onto a special transfer paper which is then placed onto the surface of the item to be printed. Pressure and heat of around 180-200 Celsius are then applied transforming the ink into a gas making it penetrate the surface of the substrate before cooling. 

The method produces stunning, full-color and long-lasting images that are embedded within the product.

Sublimated uniforms by product customizer

Sublimated products: from shirts to paper, what kind of products can be sublimated? 

Also known as all-over-printing, sublimation printing can be applied to a wide array of products . Designs can be applied seamlessly across the entire surface of a garment. This makes this method highly popular in the apparel industry for items like t-shirts, hoodies, swimsuits, and sports uniforms.

It is also popular for  accessories such as hats and socks.It is especially popular for product customization, including sports and work uniforms or unique promotional items for gifts or businesses. This method delivers high-resolution, vibrant prints of names, numbers, logos, and even full-color photographs that remain durable through washing without compromising fabric breathability.

custom sweater

Furthermore, in the home decor industry sublimation printing can be used to add a personal touch to cushions, pillowcases and even banners and wall art. While in merchandise, gifts and homewares, it is effective with products like ceramic mugs, coasters, flags, phone cases and mousepads affording rich and durable colors.

custom pillow

In terms of choice of materials, it works best on 100% polyester fabrics, polyester blends and polymer-coated materials such as woods, metals, glass, plastics and ceramics.

Pros and cons of sublimation prints

Like any traditional printing method, sublimation printing has advantages and limitations:

Sublimation technique Pros

  • Sublimated images aren’t just applied on top of the material, they’re embedded into the substrate, making them highly resistant to fading, peeling or cracking;
  • Designs can be transferred from seam-to-seam across a garment ;
  • It can be applied to a wide range of coated materials including polyesters, ceramics, wood, plastic, metal and glass;
  • It allows for full-color, photographic-quality prints with no additional setup costs for multiple colors;
  • Sublimation printing, using dry inks, infuses ink directly into materials, reducing waste and environmental impact, making it more eco-friendly than other methods.

Limitations of sublimation

  • Sublimation only works on different materials that contain a high percentage of polyester. It doesn’t work on natural fibers like cotton or silk;
  • It’s unsuitable for block color or exact placement prints;
  • Sublimation special ink is transparent, so it only works on white or light colors substrates where the ink’s colors can pop. Prints would not be visible on black material;
  • Color mismatch can occur, where colors are different to what appears on screen, although improvements can be made with RIP software and color correction;
  • Accidental folds or moisture can cause white streaks where the ink hasn’t reached. The movement of the transfer sublimation paper could cause a blurred shadow effect, or “ghosting”.

Sublimation Printing vs Screen Printing

What are the main differences between sublimation and screen printing?

  • Screen printing applies ink through a stencil onto the substrate and is best suited for high-volume runs, and simple designs of few colors;
  • Sublimation offers more flexibility for full-color and intricate durable designs , but is not as cost-effective for large quantities;
  • Sublimation prints seam-to-seam while screen prints on a smaller area.

Sublimation vs DTG and DTF Printing

Here are the key differences between Sublimation printing and DTG:

  • Direct-to-garment printing is similar to sublimation in that it’s great for full-color prints, but it’s designed specifically for fabrics including cottons and cotton-blends ;
  • Unlike sublimation, DTG can print onto any base color, although is restricted to the area of the platen;
  • Additionally, it is faster than sublimation because it prints directly rather than as a transfer process.

And what about DTF?

  • Direct-to-film involves printing onto a special film and then transferring it to the substrate using heat;
  • While it can be more versatile than sublimation in terms of the substrates it can handle, it may not offer the same level of color accuracy and durability .

Mastering design preparation: step-by-step guide to ready your file for sublimation printing

To get the best from your sublimated prints, ensuring correct file preparation is vital . Here are the key steps:

  • Design your artwork at a high resolution (at least 150-300 dpi) in CMYK or CMYK-safe RGB colors for most screen accuracy;
  • Ensure the files are saved in the correct format, such as .png or .ai.;
  • Use full-bleed images for maximum coverage;
  • Ensure the design matches the size of the product and ensure there are no white borders or sublimation blanks areas as these will be printed;
  • Mirror the image before printing, as it will be flipped during the transfer process.
uniforms sublimated

The sublimation printing process: guide step-by-step

Understanding the sublimation printing process is crucial for achieving high-quality results. Let’s break it down into manageable steps:

  1. Design creation: Create your design using graphic design software like Adobe Photoshop or Illustrator. Ensure your design is in CMYK color mode for accurate color reproduction;
  2. Printing the transfer: Print your design onto special sublimation transfer paper using sublimation ink. Remember to mirror your image before printing;
  3. Preparation of the substrate: Ensure your substrate (e.g., polyester fabric or polymer-coated item) is clean and free from dust or lint. Pre-press the substrate to remove any moisture;
  4. Positioning the transfer: Carefully position the printed transfer onto your substrate. Use heat-resistant tape to secure it in place and prevent shifting during the transfer process;
  5. Heat press application: Place the substrate with the transfer into your heat press. Set the temperature, pressure, and time according to the substrate manufacturer’s recommendations. Typically, settings around 380°F (193°C) for 30-60 seconds work well, but always verify for your specific materials;
  6. Cooling and peeling: After the pressing time is complete, allow the substrate to cool before carefully peeling away the transfer paper. This moment reveals the magic of sublimation – your design should now be permanently bonded to the substrate, ready to withstand wear and washing;
  7. Final inspection: Check the transferred design for any imperfections or missed areas. If necessary, you can touch up small areas with a heat press pillow and re-press.

Troubleshooting common sublimation printing issues

Even experienced sublimation printers encounter issues from time to time. Here are some common problems and their solutions:

  1. Ghosting or double images: Movement of the transfer paper during pressing. Solution: Use heat-resistant tape to secure the transfer paper and ensure your heat press applies even pressure;
  2. Faded or dull colors: Incorrect temperature, pressure, or time settings; old or low-quality ink. Solution: Verify and adjust your heat press settings; check ink quality and replace if necessary;
  3. White lines or streaks: Clogged print head nozzles or misaligned print heads. Solution: Perform a nozzle check and cleaning cycle; align print heads if necessary;
  4. Color shifting: Incorrect color profiles or substrate not suitable for sublimation. Solution: Use the correct ICC profile for your printer and ink; ensure you’re using polyester or polymer-coated substrates;
  5. Blurry or fuzzy prints: Moisture in the substrate or transfer paper. Solution: Pre-press your substrate to remove moisture; store transfer paper in a dry environment.

Sublimation printing and customization: streamlining your processes with Zakeke

As we’ve already said, sublimation printing shines in product personalization , from clothing and uniforms to accessories. 

But how can an ecommerce business start selling custom sublimated products without burdening its design team? Here’s where Zakeke comes into play: a software solution that unlocks smooth product personalization while offering advanced 3D visualization and immersive Augmented Reality and Virtual Try-On experiences.

custom uniforms

The best part? Zakeke not only enhances the shopping experience, but it streamlines and improves merchant workflows thanks to unparalleled adaptability and nifty automation capabilities.

In the web-to-print and customization realm, the right software is crucial for maximizing potential and ensuring high-quality, precise custom prints. Zakeke meets diverse printing needs , easing design and friendly printing processes and reducing manual design work. It automates the creation of custom sublimation-ready files , optimizing artwork and ensuring accurate color reproduction.

It adapts to your printing techniques, integrates with your workflows, and automates the production of print-ready files also for sublimation or engraving. In particular, it includes advanced files like nested and stacked ones with all the different print areas positioned in a pattern compatible with your printing process. 

Whether you’re trying to elevate your catalog or the one coming from a print on demand platform, Zakeke will seamlessly integrate into your current tech ecosystem. It will provide you the fulfillment options you need to increase volumes, revenues and automation. 

sublimated uniforms

In other words, Zakeke enables effortless print personalization . A simple plugin installation on your e-commerce website allows customers to design their dream products. They will design their sublimation shirts or sports uniforms without needing any design skills.

Curious about enhancing your printing workflow with Zakeke? Kick off your no-cost trial or set up a quick demo today!

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Print Customization: A Trend! Want to ride the wave and see if it’s right for your business? Try FREE online personalization with Zakeke, no hassles for your team. It’s free, try now!

Frequently Asked Questions

Is sublimation printing better than inkjet?

Sublimation printing and inkjet printing serve different purposes and have distinct advantages. Sublimation printing is superior for creating vibrant, long-lasting designs on polyester fabrics and polymer-coated materials. It produces durable prints that won’t crack, peel, or fade easily. However, inkjet printing is more versatile in terms of the materials it can print on, including paper and various fabrics. It’s also generally more cost-effective for small runs or home use. The choice between the two depends on your specific needs, materials, and production volume.

What is needed for sublimation printing?

To get started with sublimation printing, you’ll need:

  • A sublimation printer (or a converted inkjet printer)
  • Sublimation ink
  • Sublimation paper
  • A heat press
  • Blank substrates (polyester fabrics or polymer-coated items)
  • Design software
  • Heat-resistant tape
Can any printer do sublimation work?

Not all printers can be used for sublimation printing. You need either a dedicated sublimation printer or a compatible inkjet printer that can be converted for sublimation use. Epson EcoTank printers are popular choices for conversion. However, it’s important to note that once a printer is converted for sublimation, it can’t be used for regular printing again. Always check the printer specifications and compatibility before attempting to use it for sublimation.

What types of designs work best with sublimation printing?

Sublimation printing excels with:

  • Vibrant, bold designs
  • Full-color, realistic images
  • Gradients and color blends
  • Intricate patterns and details
  • All-over prints on garments

The process allows for unlimited colors without additional cost, making it ideal for complex, colorful intricate designs that would be challenging or expensive with other printing methods.

How long do sublimation prints last?

Sublimation prints are known for their durability. When done correctly on appropriate materials, sublimation prints can last as long as the substrate itself. The dye becomes part of the material, resisting fading, cracking, or peeling even after numerous washes. However, exposure to harsh chemicals or prolonged direct sunlight can affect the longevity of the print. With proper care, sublimation prints on garments can maintain their vibrancy for years.

 

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