dyesublimation

Dye-sublimation, or dye-sub, is a digital printing process that uses heat to transfer dye in sublimation form from a carrier paper to a polymer-coated substrate. The dyes sublimate from solid to gas under heat, then diffuse into the coating and form a durable bond with the substrate's surface. Because the dye becomes part of the coating, sublimation prints are typically vibrant and resistant to weathering and washing on compatible materials. Inks are usually CMYK dye-sub inks.

The workflow generally involves designing an image, printing it in reverse onto sublimation transfer paper using specialized dye-sub inks, placing the transfer on the target item, and applying heat and pressure with a heat press. Temperature ranges are typically about 180-200°C (356-392°F) for 60-120 seconds, depending on substrate and equipment.

Substrates and compatibility: Dye-sublimation works best on white or light-colored polyester fabrics and polymer-coated hard surfaces such as mugs, ceramic tiles, metal with polymer coating, and certain plastics. Uncoated cotton or glass is not suitable unless a compatible coating is applied. Dark substrates require additional coating or a white base layer to reproduce colors accurately.

Applications and considerations: Dye-sub printing is common for customized apparel, promotional items, and photo-quality gift items. Advantages include bright, full-color results with a soft hand on textiles and good durability. Limitations include substrate restrictions, potential color shifts with different coatings, and the need for proper curing to prevent fading or cracking.