DYE SUBLIMATION PRINTING - AN OVERVIEW
WHAT IS DYE SUBLIMATION PRINTING?
Sublimation printing is the application of sublimation inks onto a surface using a heat press to provide the required combination of heat, time and pressure. This combination causes the inks to be converted from a solid to a gaseous state enabling them to penetrate the sublimatable surface so that a permanent, full colour image is formed. The colour penetrates the surface of the item so that the result is colourful, long lasting and resistant to scratching unlike some other printing methods that merely print onto the surface of the item.
Dye sublimation printing is always done on a polyester, polymer, or polymer coated item. At high temperatures, the solid dye converts into a gas without ever becoming a liquid. The same high temperature opens the pores of the polymer and allows the gas to enter. When the temperature drops, the pores close and the gas reverts to a solid state. It has now become a part of the polymer. For this reason true dye sublimation cannot be done on natural materials such as 100% cotton. Natural fibres and non-coated materials have no "pores" to open.
WHAT ARE DYE SUBLIMATION INKS?
Dye sublimation inks are basically a formulation of different colored dyes suspended in liquids that will pass through a digital printer.
WHAT CAN BE SUBLIMATION PRINTED?
You can sublimation print onto a wide variety of items provided that the surface is suitable for sublimation printing. We offer both 'hard' and 'soft' items that are suitable for sublimation printing - full details of our extensive range can be found on our imprintables pages.
Hard items including specially coated plaques, signs, placemats, coasters, tiles, mugs, metal and keyrings.
Soft items including polyester fabric, canvas, umbrellas, t-shirts, polo shirts, cushions, car sun screens and even doormats! A sublimation print on a suitable polyester fabric is permanent, feels like part of the fabric with no 'hand' and will not crack, peel or fade.
WHAT CANNOT BE SUBLIMATION PRINTED?
Cotton fabric and garments - because dye sublimation printing is always done on a polyester, polymer, or polymer coated items (see above). It is possible to sublimation print a cotton fabric but the image will wash out within a few washes. We offer a range of spun polyester t-shirts for sublimation printing including the Vapor range of 'wickable' and 'performance' t-shirts in a range of colours.
Other items that may have a polyester/polymer coating but which are unsuitable as they are unable to withstand the temperatures required for dye sublimation printing.
HOW DO YOU ACTUALLY PRODUCE A PRINTED ITEM?
For this example we will explain how to produce a 10 cm square coaster.
Firstly you would produce your image using a suitable graphics package, such as Corel, Photoshop or Illustrator. You would usually make the image size a little larger to allow for the image to 'bleed' over the edge of the coaster so that there is no white edge showing.
The image is then printed out, mirror imaged, onto sublimation paper. The resulting transfer is then laid face up and the coaster is laid onto it, printable side down. The image is aligned in position and then heat resistant tape is used to hold the transfer in place so that the coaster can be turned over to be heat pressed with the transfer face up.
For a coaster the heat press would be preheated to 200° centigrade and the coaster would be 'pressed' for 60 seconds at a medium pressure.
At the end of the heating time the heat tape and paper is removed and you have a finished coaster which is glossy, scratch resistant with bright, vibrant colours.
WHAT EQUIPMENT IS NEEDED FOR DYE SUBLIMATION PRINTING?
Epson Printer
Dye sublimation inks
Sublimation paper
Heat press or wraps
PRINTERS
Printers used for sublimation printing are those with Piezo electric print heads made by Epson. It works by means of a tiny crystal in the head that pulsates with a small electrical charge forcing droplets of ink onto the paper with virtually no heat being generated. This print head is fitted in all Epson desktop printers and many large format printers and is the only print head that will work for sublimation printing.
The thermal heads are found in 'bubble jet' printers like HP, Canon and Lexmark work by heating up the ink which when it expands forces a droplet of ink onto the paper. The problem with this type of print head for sublimation is that the heat affects the inks as they are forced through the head and the ink will accumulate inside eventually clogging the print head.
DYE SUBLIMATION INKS
Dye sublimation inks are available in cartridges or as bulk supply systems for a range of Epson printers. We distribute the Tropical Graphics range of ArTainium sublimation ink - a tried and tested dye sublimation ink used by over 10,000 customers worldwide. Please see our inks page for full details of our range of supported A4, A3 and A2 printers. You need to set up a special profile on your computer system so that it prints the sublimation inks correctly. We supply full details of how to set up the colour profiles on your computer and offer ongoing technical support.
SUBLIMATION PAPER
Dye sublimation inks need a paper that allows the ink to remain on the surface of the paper. We offer a range of sublimation transfer papers - please see our paper page for more information.
HEAT PRESS OR WRAPS
For 'flat' items such as plaques, coasters, tiles, garments, etc, you will need a flatbed heat press. It is not possible to obtain the consistency of heat and pressure required using a home iron.
For mugs and glasses you can use a mug press or alternatively we offer economical mug wraps which enable you to sublimation print mugs in a standard oven.
A range of alternative heat presses are also available for specialised items like bags, caps and plates. Full details on the range of Europa Leisure heat presses can be found on our heat press pages.
If you would like further information please give us a call on 01844 274354, we are always happy to discuss your requirements with you.
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