To choose the best printing device for your business, understanding the differences in quality, cost, and material compatibility between them is key. With a surge in print-on-demand printing, businesses are earning thousands of dollars.
Here, two core printer technologies have been in debate: sublimation vs. DTG printers. Both, known for their remarkable printing capabilities, are good choices for business owners. However, the question remains: Which one stands as the preferred choice?
This guide will discuss the differences between them and how they benefit various businesses. And end up with a conclusion on which one is more favourable for your printing needs. Let’s dive into this detailed analysis of the sublimation printer vs. the DTG printer to make an informed decision that will definitely benefit you in the long term.
What is Sublimation Printing?
As the name suggests, sublimation printing involves applying controlled heat and pressure to infuse dyes directly into polyester materials or polymer-coated items through the “sublimation” process. The process uses a sublimation printer, a specialized device that prints designs onto sublimation paper. This paper is not just a standard paper, but a specially designed one for these printers. The sublimation inks used here produce designs that fuse with the fabric and appear to be part of it. That’s why it doesn’t crack or peel. The resulting prints are vivid, durable, and long-lasting. They are best suited for promotional products and print-on-demand fabrics.
How does it work?
The following steps are essential to carry out sublimation printing successfully:
- The process begins by creating a design to be printed. It is done using a graphic design software. Once the designs are created, they are printed on sublimation paper in reverse (mirror image) using a sublimation printer and sublimation inks. The ink is solid on the paper at this stage.
- Using the heat press, place the sublimation paper on the item you want to print on, with the printed side down. A heat-resistant tape will help firmly hold the design in place.
- When the heat and pressure are applied, the solid ink fuses into the material being printed and changes directly into a gaseous phase (without passing through a liquid phase). This is called sublimation. This results in inks bonding with the item’s surface.
- Sublimation printing is compatible only with polyester fabrics or polymer-coated surfaces. So when choosing, take care of this step and select materials that meet the criteria.
- After printing is complete, wait for the material to cool down. Then carefully peel off the paper. This ensures the vibrant prints are infused into the material, resulting in permanent prints that won’t crack.
Pros
- Produces vivid and vibrant colors that last a long time.
- Ink infuses into the fabric and becomes part of it, which prevents cracking, peeling, or fading with washing.
- Creates smooth, seamless prints with no raised surfaces.
- Great for detailed designs and photo-quality images.
- Works with a variety of applications, including mugs, tumblers, caps, and others.
Cons
- Only works on polyester or polyester-blend fabrics and polymer-coated items; it does not work on natural fibres like cotton or other surfaces.
- Limited to printing on light or white-colored fabrics.
- Setup and equipment costs can be high.
- Production speed may be slower due to heat-transfer steps.
What is DTG Printing?
DTG, or direct-to-garment printing, works similarly to inkjet printing, but instead of paper, it prints on fabric. The printing process uses a specialized DTG printer that prints directly onto the fabric. Ink bonds well with the pre-treated blanks, resulting in high-level, detailed designs that feel soft. Thus, one machine does all the work, and no other equipment is needed. DTG printing works best with intricate patterns and small-scale orders.
How does it work?
Here are the essential steps involved in the DTG printing:
- Before beginning the printing process, the fabric is treated with a pre-treatment liquid. This step is crucial, as it ensures that the inks bond perfectly and high-quality, durable prints are produced.
- As with the sublimation printer, the design is created using digital graphic design software. The printer reads the design.
- Now, interpreting the design from the computer, the printer prints the design directly onto the fabric. The printhead sprays ink using white ink and different colored inks.
- Ink deposits on the pre-treated fabric bond with it, creating detailed, high-level, complex patterns. This is where DTG printing stands out, as this level of detailing is impossible to achieve with other methods like dye-sublimation printers and screen printing.
- Then it’s time to solidify the designs. This means you need to provide heat to cure the print. Some advanced DTG printers carry out the entire process – printing and curing –using the built-in heat setting in the same equipment. However, sometimes you need a heat press to cure the design. This stage is crucial and must be performed accurately using the appropriate temperature settings. It will result in permanent designs that last after washing off.
Pros
- It performs effectively on natural fabrics, particularly those made entirely of cotton.
- Produces detailed, colorful prints, including on dark fabrics, with white ink.
- Fast production speed and easy to use.
Cons
- Prints sit on the fabric surface, which may fade, crack, or peel over time with washing.
- Less durable than sublimation on synthetic fabrics.
- Ink colors might be less vibrant compared to sublimation on polyester.
- Requires pretreatment of fabric, adding extra steps and cost.
DTG vs Sublimation: The Key Differences
The two techniques differ largely and have very different resulting prints. So what are they? Let’s discuss them in detail below.
Fabric Compatibility
DTG and Sublimation printing both work on different materials. Dye-sublimation only works on limited fabrics, such as polyester, poly-blended fabrics, spandex, and nylon. For other materials, a polyester coating is essential. Thus, cotton or other natural fibres are not suitable for sublimation printing.
On the other hand, DTG printing is best for natural fibers, especially 100% cotton. It also works well on cotton-blended fabrics.
Print Quality
As the ink turns from solid to gas, fusing into the fabric in the sublimation process, the resulting quality is very good, and the prints feel soft. It creates vibrant, long-lasting, and photo-realistic prints with smooth color gradients. So, it is ideal for all-over designs on polyester materials.
With DTG printing, you can print very complex designs with intricate patterns and photos. It will result in highly detailed, accurate colors. However, when using dark colored fabrics, colors might seem less vibrant.
Setup Cost
Though DTG requires a higher initial investment for setup, for example, you can buy the equipment for $15,000 and start your print-on-demand business. At the same time, there are no long-term costs except for the pre-treatment liquid.
In comparison, a Sublimation printer will cost you less for initial setup, i.e., around $25,00, which could be reasonable. But that’s not it, you have to take into account the ongoing costs for specialized sublimation inks and paper, too.
Running Cost
DTG printing has a cost structure better suited to small to medium order volumes. The per-print cost includes ink, pre-treatment liquids, and substrates. In general, DTG prints cost between $0.50 and $3.50 per piece, depending on the garment color and the complexity of the design.
Sublimation printing, on the other hand, shows advantages when scaling up production. Sublimation prints are integrated into the fabric, reducing the need for post-print treatment and saving time and materials. As order volumes grow, these efficiencies significantly reduce per-unit cost. This makes sublimation more economical for large-scale productions and all-over print designs.
Production Speed
As with DTG printing, printing is the final stage in finalizing the blank product. That means the fabric/blank comes stitched and just has to be printed, reducing the time required to prepare the final product. When it comes to printing efficiency, the blanks must be pre-treated before printing. This results in a longer final printing process.
For sublimation, when you need overall printing on the fabric, it is done from scratch. This involves cutting, printing, and then stitching, which is a lengthy process. But the printing process is quite quick, as there is no need to pretreat the fabric.
Durability
As discussed earlier, sublimation prints fuse into fabric fibres and become a part of the fabric. This process makes them feel durable and resistant to fading.
In comparison, DTG prints sit on top of fabric, appearing to be textured. These prints may peel off or fade with multiple washes. Therefore, careful maintenance is needed to ensure the prints last longer.
Environmental Impact
Direct-to-garment printing uses water-based inks that are eco-conscious and non-toxic, making them a safer printing option. At the same time, pre-treatment liquid may contain chemicals that can be harmful to the environment.
On the other hand, sublimation inks are specialized heat-transfer dyes made mainly of water and are considered eco-friendly. But it depends on energy consumption during the process.
Should you choose DTG or Sublimation?
Now that you know the difference, you may know both DTG and Sublimation printers serve different needs. Now comes the moment to make the final choice:
Choose DTG if:
- Working with cotton fabric with complex designs
- Minimal setup
- Dealing with small to medium-sized orders
- complex designs
Choose Sublimation if:
- Working with synthetic fabrics
- Durable and permanent prints
- Large orders
- You are a startup
Ultimately, choosing the right process is about your preferences and business needs. Consider the above points to determine which method best suits your needs.
Conclusion
To sum up, you know that both printing methods serve incredibly well. However, it’s recommended to choose a DTG printer for cotton fabrics, particularly for small to medium-sized printing batches and designs that require intricate detailing. Sublimation printing is suitable for polyester materials and bulk production, making it great for sportswear, promotional items, and home décor.
Besides, whatever equipment – DTG or dye-sublimation – you choose, DTF Linko covers it all for you! Contact us today to discover the best and most affordable printing solutions that deliver the quality and reliability your business deserves.
