Dye Sublimation Printing
Dye sublimation printing is a process that uses heat to turn specialized dye-based ink into a gas. The gas penetrates polyester fibers or a polymer-coated substrate, embedding the color into the material rather than leaving the ink primarily on its surface.
This makes dye sublimation especially well suited to fabric and certain rigid substrates. Compared with UV-curable ink or latex printing, dye sublimation can produce exceptionally vivid, colorful results on fabric. On rigid substrates, it can create a dimensional-looking appearance, particularly with a gloss finish. Because the ink is embedded into the material, the printed surface has no noticeable layer of ink.
What are the benefits of dye sublimation printing?
Dye sublimation printing offers several benefits, including:
- Water resistance
- Scratch resistance
- Durability
- Photographic-quality reproduction, depending on the printer and application
How does dye sublimation printing work?
Dye sublimation printing requires disperse dye sublimation ink, a polyester fabric or polymer-coated rigid substrate and transfer paper. Fabrics should contain at least 70% polyester, with 100% polyester being ideal.
The image is first printed onto specially formulated transfer paper as a mirrored or wrong-reading image. Heat, time and pressure are then applied between the transfer paper and substrate. The heat turns the ink into a gas, allowing it to penetrate the polyester fibers or polymer coating. Once the process is complete, the image becomes right-reading and is embedded in the material.
What materials can be used for dye sublimation?
Dye sublimation can be used on:
- Fabrics containing 70%-100% polyester
- Rigid substrates with a polymer coating designed for sublimation
- Aluminum with white gloss, white matte or white semi-gloss finishes
- Ceramics
- Phenolic and tempered hardboard with a dye-sublimatable coating
- Other flat substrates that can withstand temperatures up to 400°F for periods of up to 90 seconds and have a suitable polymer coating
What products use dye sublimation printing?
Smartpress uses the dye sublimation process for a variety of fabric and rigid products, including:
- Tension fabric displays
- Silicone edge graphics (SEGs)
- Feather flags
- Table throws
- Projects via Custom Quote, such as:
- Fabric banners
- Fabric backdrops
- Aluminum metal prints
What should I keep in mind when preparing artwork?
A few file-preparation tips can help you get the best results from dye sublimation printing:
- Keep important text and logos away from the perimeter of the artwork. A 1% margin on all four sides provides a 98% live area.
- Avoid white or reverse text set in serif fonts smaller than 12 pt.
- For fabric products, include at least 1″ of bleed whenever possible.
- For color-critical work, preview RGB images in CMYK to get a better idea of how the final print may look.
- For fabrics or rigid substrates with a matte finish, use swatches from the PANTONE Uncoated or PANTONE Uncoated Process libraries when selecting PANTONE colors.
- For rigid substrates with a semi-gloss or gloss finish, use swatches from the PANTONE Coated or PANTONE Coated Process libraries.
- Allow for potentially longer turnaround times, as dye sublimation involves a more involved imaging process.
Have more questions about dye sublimation printing? Contact customer service and we’ll be happy to help.
