What is Sublimation Printing? - Ordant

Sublimation is a popular surface decoration process for creating short runs of custom sportswear, soft signage (display graphics on fabrics), decorated textiles, photo panels, building materials, and promotional products.    

When controlled amounts of heat or pressure are applied to either a printed transfer paper or polyester-coated surface, the colorants in sublimation inks become gasses that permeate the surface of the item being decorated. The ink doesn’t alter how the printed surface feels. Dive into the details of sublimation printing processes with a closer look.

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Two sublimation processes

The sublimation transfer process gives shops the versatility to decorate either rolls of fabrics or rigid surfaces such as aluminum. acrylic, stretched canvas, snowboards or wood panels

In this process, the inks are printed on specially treated sublimation transfer papers. A heat press applies the controlled amounts of heat and pressure needed to transfer the inks from the printed paper to the fabric or object being decorated.  

The direct sublimation process enables businesses to decorate long runs of fabrics that are up to 197 inch wide to make seamless backdrops for decor, stage sets, theaters, and trade show exhibits. The direct process eliminates the time and expense of printing on a transfer paper first but requires treated fabrics to produce the best results.

Some “hybrid” 10-ft. and 16- ft.- wide printers are designed for both sublimation transfer or direct sublimation. Some of these superwide dye-sub printers have built-in heaters to sublimate the inks into the fabric. This eliminates the need to unload a printed roll and run it through a separate superwide rotary heating calendar to convert and dry the inks.

Benefits of Sublimation

The use of sublimation printing is rising partly because it offers some important durability and sustainability advantages compared to direct painting.

As a result, there has been a rapid growth in the demand for sublimated products and ongoing improvements in sublimation technology. Today, print-service providers can choose from a huge variety of sublimation printers as well as hundreds of different types of sublimation-ready textiles, photo gifts, and promotional products.

Sublimation printing provides low-cost-of-entry business opportunities for start-up e-commerce retail businesses. Established graphics and commercial printing businesses can use sublimation printing  to expand their product offerings or enter new markets, such as interior decor or promotional products. .

Here are some benefits:

Natural feel:

Unlike screen-printing or heat-transfer surface-decoration processes, sublimation printing doesn’t alter how the printed garment or photo product feels to the touch. Sublimation is a popular method of decorating sportswear, swimsuits, leggings, and other apparel that will be worn close to the body.

Durability:

Because the inks are embedded beneath the print surface, the printed image is resistant to water, abrasion, cracking, and fading. Sublimated photographs on poly-coated metal panels don’t need to be framed behind UV-filtering glass or acrylic to resist fading.

Vibrant Colors:

Most dye-sublimation printers use CMYK inks. But some printers are also built to include additional colors such as violet, orange, fluorescent yellow or fluorescent pink. These combinations can achieve a brighter range of colors. Fluorescent yellow gives safety and cycling apparel greater visibility in dangerous conditions.

Image Quality:

Instead of forming colors by placing dots of ink directly on the fabric, the sublimation process produces continuous-tone images. Correctly sublimated photographs don’t show any dots, even when viewed up close.

Cost-Effective Sign Option:

Sublimation inks cost less than the UV-inks used to produce durable indoor and outdoor prints for trade shows and events. Sublimated fabric graphics for trade-show exhibits are less costly to ship than signs printed on vinyl or rigid boards. The fabric typically weighs less and can be folded or rolled up into a small package. Because of its durability, the sublimated fabric graphics can be re-used at multiple events.

Sustainability:

Because polyester fabric can be reused and recycled, it reduces the volume of landfill waste compared to signs made from vinyl and some rigid materials.

The sublimation inks are water based, and don’t contain the solvents or photo initiators used to make eco-solvent or UV-curable inks.

Makers of fabrics for fashion and apparel like dye-sublimation because it doesn’t require the printed textiles to be steamed, washed, and dried before they are cut and sewn into garments, bedding, or upholstery products.

It also reduces the use of water and energy.and allows garments and upholstery to be manufactured only in the sizes, colors, and patterns customers have ordered. This keeps more unsold garments out of landfills.      

Sublimation Printers

Entry-level sublimation printers (8.5- to 24-inches wide) and heat presses are available for start-up home-based businesses who want to produce and sell small, customized or personalized products. These printers can be used to decorate items such as coffee mugs, luggage tags, coasters, ornaments, photo plaques, drinkware, pillow covers, and promotional products.

Sublimation printers ranging from 44 to 64 in.are used to make fashion, jerseys, costumes, bedsheets, blankets, tapestries, snowboards, metal photo panels, and some types of displays.  

Larger printers – from 76 to 196 in. wide – are available to make soft signage and display graphics, including seamless, easy-to-ship backdrops and displays for trade shows, museums, entertainment venues, theme parks, and retail stores.

These grand-format printing companies often handle outsourced work from print-service providers that don’t have the demand or capacity for printers and heat calendars that can handle rolls of materials that are 3 meters or 5 meters wide.

Challenges and Limitations

Color management can be tricky:

It’s impractical for manufacturers to develop accurate profiles that include all the variables in both the printing and heat-transfer steps. The specialized RIP software offered with your sublimation printer can be helpful, but you must learn how to troubleshoot any color control problems that arise with the specific products you are decorating.

Dye-sub experts recommend experimenting with different combinations of settings and documenting which one produces the best results in your shop.

It’s critical to set up a predictable, repeatable workflow for each sublimated product offered. New color management tools are being developed for digitally printed fabrics. Specialized training is also available. .

The sublimation process doesn’t work on all materials:

It can be used (with different results) on coated and uncoated polyester fabrics and poly-cotton materials that have a high level of polyester.

The sublimation process doesn’t work on garments made with natural fibers such as cotton and wool because the fibers don’t open up when exposed to heat.

To expand the use of fabrics that can be printed, makers of sublimation printers, inks, and transfer paper are developing new types products that will owners of wide-format pigment-ink printers to use the heat calendars they use for sublimation to also transfer pigment-ink images to cotton and other natural fabrics.  

Metals and plastic items require a polymer coating in order to be decorated with sublimation inks. Ceramics and glass can also be sublimated with the right kind of treatments.

White inks aren’t available:

This means sublimation works best on white or light-color fabrics because white sublimation inks aren’t available to produce a base layer for vibrant, predictable colors.

There are lots of opportunities for errors:

For example, if the fabric stretches, wrinkles, or folds over during the transfer process, the image won’t print or transfer correctly.

If a transfer paper is oversaturated with ink, the colors will bleed or run. The colors won’t look as vibrant if the operator uses the wrong combination of time, heat, and pressure to transfer the ink to the product.

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A good way to learn about how to sublimate is to start with a low-cost entry-level printer and heat press.

Suppliers of equipment and materials have provided numerous videos, blog posts, and webinars that explain how to avoid or troubleshoot common problems.  

Setting Up a Workflow

Setting up repeatable, efficient, quality-controlled workflows for each product your shop offers is key to achieving greater profitability in your business.

Once you have an efficient workflow established, you can use Ordant software to automate the process of reaching out to potential customers, estimating potential jobs, and scheduling, shipping, and invoicing jobs.

You can also integrate web-to-print storefronts that enable you to accept online orders from either business customers or consumers. Incoming, prepaid, pre-approved job files can be automatically routed to the appropriate printer being used for production.

With Ordant, it is easy to incorporate sublimation workflows alongside workflows for products made on UV flatbed printers, eco-solvent wide-format printers, label printers, direct-to-garment printers, or offset presses.

Sublimation involves a sophisticated process known as dye-sublimation transfer, where digital images are first printed using a sublimation printer and special inks onto sublimation transfer paper. These images are then transferred onto a polyester or poly-coated item through a heat press, where the ink turns into a gas and infuses into the substrate, creating stunning and durable results.

This method is celebrated for its ability to produce vibrant, full-color images on a wide range of products—from hard goods like coffee mugs and aluminum photo panels to soft goods such as t-shirts and pillowcases. The end products are not only visually impressive but are also durable and less prone to fading, as the ink becomes a part of the substrate itself.

Sublimation paper acts as the essential 'carrier' for sublimation ink, enabling it to be transferred onto various items. This specialized paper securely holds the ink until it is pressed onto a substrate using a heat press. The process might seem straightforward, but the choice of sublimation paper can significantly influence the quality of the final product. This is because different types of sublimation papers are engineered for different kinds of substrates, which are categorized broadly into soft and hard substrates.

It’s important to remember that using regular paper for sublimation transfers will not yield satisfactory results. Sublimation papers contain coatings that manage the ink's release and adhesion to the substrate, which regular paper lacks, making it unsuitable for achieving the high-quality outcomes expected in sublimation printing.

Sublimation ink is the lifeblood of the sublimation printing process, often described as the "water" of this vibrant ecosystem. This eco-friendly ink is a unique formulation of water and heat-reactive dyes, devoid of solvents or any additional chemicals, making it a greener choice for printing. Leading the market in this space is Epson, known for their commitment to sustainability and quality.

When it comes to color and vibrancy, sublimation inks from Epson are unparalleled. They deliver rich, eye-catching colors that are deeply infused into the substrate, creating durable and vivid prints. This level of quality is achieved through years of research and development, ensuring their inks perform exceptionally on a wide range of substrates.

While sublimation ink can technically be used for regular printing, it is not advisable due to its high cost and the specific color output it generates, which may not be suitable for standard document printing. Essentially, while you can use sublimation ink for regular printing tasks, its specialized nature and cost make it impractical for such uses.

A sublimation heat press is a specialized piece of equipment essential for transferring designs onto substrates through the sublimation process.

Characterized by its swing-away design, this type of heat press offers superior functionality for sublimation tasks by providing the operator with full access to the pressing table. This accessibility is crucial for placing and adjusting materials accurately under the heat platen.

For a heat press to be effective in sublimation, several key features are necessary:

• A swing-away top that allows complete access to the pressing area, facilitating easier layout and adjustment of transfer materials.
• Even pressure distribution across all four corners of the press to ensure uniform image transfer.
• Consistent heat distribution across the entire surface to prevent cold spots that could lead to incomplete transfers.
• Digital controls and timers for precise temperature and time setting, which are critical for achieving optimal results.
• Robust construction, typically from solid steel, to withstand the rigors of heavy and continuous use.

One exemplary model that checks all the boxes is the Geo Knight DK20S, a flagship 16x20 swing-away heat transfer press renowned for its reliability and performance. The DK20S operates within a temperature range of 375° to 425° F and can exert between 40-80 psi, ensuring that you achieve consistent results with every use, essential for both high-quality and high-volume production.

When choosing a heat press for sublimation, it's crucial to select a machine that not only meets the technical demands of sublimation but also one that fits the scale of your operations. Whether you’re outfitting a small boutique or a large production facility, the right heat press is a pivotal investment. The Geo Knight DK20S comes highly recommended for its comprehensive features and robustness, making it a worthwhile cornerstone for any serious sublimation business. Remember, a quality heat press is a versatile tool that can handle various other fabric decoration techniques, such as vinyl transfers and rhinestone applications, thereby enhancing its value and utility in a diverse crafting or garment production environment.

What items can be transformed through sublimation? The possibilities are vast, ranging from full-color name badges and coffee mugs to metal art prints,, home decor items, and personalized keepsakes. The versatility of sublimation makes it a popular choice for creating unique and vibrant products.

At its core, sublimation ink has a natural affinity for polyester, bonding well with poly-coated materials due to its oil-loving molecular structure. This process involves a sublimation coating, a clear polyester-based material that captures the dye in an extremely tight pattern, ensuring sharp, high-resolution results. Traditionally, sublimation works best on white and light-colored materials and fabrics because there is no white sublimation ink available. This limitation means that sublimation cannot traditionally be applied to dark materials directly.

The market for blank sublimation products is currently booming, with an ever-expanding array of high-quality, trendy items becoming available. As new products continuously enter the market, tools like laser cutters enhance the potential for customization even further, allowing users to create their own bespoke sublimation blanks from a variety of pre-coated materials. Whether you are looking to expand product offerings or explore new creative avenues, sublimation provides a powerful platform to turn imaginative ideas into tangible, marketable products.

Determining the right pricing for sublimation products in the retail market is a common query among creative entrepreneurs. When you’re creating high-quality, visually appealing products, it’s crucial to ensure that your pricing not only covers your costs but also generates a profitable return.

Choosing the right products from the myriad of available blank substrates is just the first step. Once you’ve mastered a new technique or design for a chosen substrate, the next crucial step is pricing. Several key factors play into effective pricing strategy: the cost of goods sold (COGS), the time it takes to produce each item, the consumables like ink and paper, as well as packaging, shipping, and marketing expenses.

To establish a competitive and profitable pricing structure, you should start by calculating these costs to determine your baseline. This will give you a clear understanding of the minimum price you need to cover expenses and the target price to ensure profitability. For a comprehensive guide on how to maximize your return on investment (ROI) and develop a detailed pricing strategy for your sublimation products, consider exploring additional resources such as the article 'The Ultimate Guide to Retail Pricing Sublimation Products'. This resource provides an in-depth look at crafting a pricing strategy that aligns with market demands while ensuring your business's financial goals are met.

Is sublimation printing a profitable venture? Absolutely, especially when you consider the relatively low startup costs and the potential for high returns on investment (ROI). For instance, if you already own a heat press, an initial investment of approximately $450 could set you up with a sublimation printer, the necessary inks, and paper, enabling you to start producing items by the end of the day. The ongoing cost of inks is modest, typically around one penny per square inch of the printed transfer, with an added equivalent cost for paper.

To better understand the potential profitability, let's consider some practical examples. An 11oz ceramic coffee mug, for instance, can be produced for around $2.00 when you add a customer’s logo or image. This mug can then retail for between $16.00 and $20.00, depending on your market. Introducing premium licensed art images can further increase the retail price. Another example is a name badge, which costs about $1.25 to produce and can retail for between $8.00 and $12.00. These examples highlight the significant markup potential and the profitability of sublimation printing.

Incorporating sublimation printing into your business is not just about immediate gains but also about building a sustainable, scalable model. This printing method is not only eco-friendly but also highly in demand due to its ability to produce vibrant, high-quality products that consumers value highly. As you expand your range of products and refine your skills, your business can grow significantly, both in product offerings and profitability. Sublimation printing offers a lucrative opportunity for those willing to invest in the necessary equipment and develop their craft.

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