Introduction
Sublimation printing is all the buzz, with many businesses opting for this remarkable printing technique. It uses a specialized printer known as a “dye sublimation printer.”
Using inks specially formulated for these machines, they transfer prints that are soft, vibrant, and photorealistic. Best of all, it’s not limited to textiles, unlike some other printing methods, and it’s quick and easy. So, you can serve your customers with printing services for a variety of products, including mugs, caps, pillow covers, t-shirts, tumblers, and more!
This article explores all about these next-level printers. We’ll walk you through the basics to answer some relevant questions. If you are a beginner or someone looking to learn all the intricacies of these printers, you are in the right place. Read till the end to learn more.
What is a Sublimation Printer?
A sublimation printer, also known as a dye sublimation printer, uses the sublimation technique to print on a substrate. It is a specialized printing device that uses sublimation ink, which is not a standard one. It combines specially formulated dyes used in the sublimation method. With these inks, the printer transfers dyes to the sublimation paper.
Precisely, the sublimation method infuses ink solids into a gas without passing through the liquid phase when controlled heat and pressure are applied. However, it should be noted that a sublimation printer can be used for polymer-coated products or polyester textiles.
The resulting prints from a sublimation printer are vibrant, full-color, and durable, and look like they’re part of the substrate. That’s the reason they can last 100+ washes with proper care.
How Does a Sublimation Printer Work?
Sublimation printers use sublimation inks. Some sublimation printer models are specifically built for sublimation printing, like LINKO X1908 and LINKO SK-1804H. While some inkjet printer models can be made to work as sublimation printers, too. However, it must be noted that not all inkjet printers can be converted. There are some specific ones, like the Epson EcoTank models, that can be easily converted.
So, sublimation printers store ink in ink tanks or cartridges. These inks travel from the cartridge through the tubes to the printhead. The printhead has nozzles with precise holes that control ink release, spraying tiny droplets and transferring designs onto the sublimation paper.
These inks on the sublimation paper are now transferred to the polymer-coated or polyester substrate. This is done using a heat press– the heat source to complete the sublimation process. The controlled heat and pressure, coupled with the right timing, infuse the ink solids into the substrate in the gas phase, without passing the liquid phase. This is called sublimation. It results in high-resolution, high-quality prints with vibrant colors. The print bonds well with the fibers of the material, now appearing to be a part of it– smooth and soft.
In this way, the sublimation printer works in tandem with the heat source to deliver exceptional results.
Equipment and Materials Required for Sublimation Printing
Keeping it clean and clear, here is the list of all the equipment and supplies you will require for the sublimation printer:
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Sublimation Printer
You can find various sublimation printers on the market. They can scale from large industrial models with larger printheads to smaller, compact models best suited for medium to small businesses. Or, as discussed earlier, you can even convert an inkjet printer (specific models) to a sublimation printer. For high-quality, high-resolution prints, it’s crucial to invest in printers that deliver long-term efficiency. Non-branded printers may be low-cost initially, but they can affect the print quality.
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Sublimation Paper
Sublimation paper is a specialty paper created just for sublimation printing. It is very different from the copy paper that is used in regular printing. What’s different is that it doesn’t absorb ink. When the printer transfers ink, it lets it sit as a solid until it is pressed onto the material with heat. There are many types and sizes of sublimation paper available. A high-quality sublimation paper is curl-resistant and prevents bleeding, ghosting, and dull colors. Additionally, you can expect a good transfer rate of up to 98%.
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Sublimation Inks
Then comes the sublimation inks– an important part of printing. Again, these are specialized inks that contain heat-activated dyes. When applying heat and controlled pressure, they sublimate nicely, fusing into the substrate. With so many ink options available for sublimation printing, you must choose one that is compatible with your printer.
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Sublimation Blanks
The sublimation technique is used on a wide range of items, including mugs, shirts, tumblers, and more. These blanks are needed, but all must be polymer-coated or polyester-based. These accept sublimation printing really well.
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Heat Source
The heat source includes different types of heat presses specific to the blanks used. Flat, mug, or tumbler heat presses are usually used for typical items. Instead, you can use a curing/convection oven to cure mugs and tumblers. While for shirts and other fabric items like pillow covers and napkins, a heat press is preferred.
Other supplies include thermal tape, spray adhesive, and transfer gloves.
What Materials are Suitable for Sublimation Printing?
The best material for sublimation includes:
- Polyester textiles
Polyester textiles ranging from 80% to 100% work perfectly for sublimation printing. When you use other fabrics, such as cotton, nylon, or other natural fibers, they may be suitable for sublimation printing. But they won’t last long; it’s a short-term solution. Additionally, these fabrics may not withstand high heat and may burn. The logical reason for using polyester is simple. When exposed to high heat, these materials melt rather than burn. This opens pores, allowing gas from sublimation dyes to infuse into the material. And the result is soft, even, and breathable prints.
- Polymer-coated items
You can use any kind of material for sublimation. Be it plastic, wood, ceramic, or other materials, make sure you coat them with a layer of polymer. Note that even a thin layer of polymer provides good adhesion for sublimation prints.
Advantages and Disadvantages of Sublimation Printing
Advantages
- Excellent print quality: The sublimation technique produces high-quality prints that are vibrant, soft, and detailed.
- Durable and long-lasting: As the inks penetrate the material, durability is guaranteed when applied to favourable materials. This print lasts longer and can withstand 100+ washes.
- Best for print-on-demand services: Ideal for one-off products and low orders, with no minimum order quantity.
- Versatile: When polymer-coated, sublimation printing can be done on various materials, including wood, ceramic, and plastic.
Disadvantages
- High initial costs: When all costs are included, setting up initially can result in a high investment. When set up, it’s best for small orders, while bulk orders incur higher costs due to more consumables.
- Material restrictions: Natural fibers are not suitable for high-temperature applications, and sublimation prints do not adhere well to non-polymer-coated materials. That’s why only polyester and polymer-coated materials are applicable.
- UV sensitivity: Sublimation prints fade faster when exposed to UV rays. But this heavily depends on ink quality.
In Which Fields Are Dye-Sublimation Printers Used?
With customized products on demand, dye-sublimation printing is applicable across various fields. The following are some major areas where the sublimation method is used:
- Textile printing
- Promotional Marketing
- Display and signage
- Photography
- Home goods
- Print-on-demand items
FAQs
Can a regular printer be used for sublimation printing?
No, regular inkjet or laserjet printers cannot be used for sublimation printing. Specific models of inkjet printers, including the Epson Ecotank model or those using a micro piezo printhead, can be converted. The sublimation printers use thermally activated sublimation inks, which require specialized equipment parts. These prevent them from clogging the printhead nozzle and causing further damage.
Is sublimation printing only suitable for light-colored materials? Can it print on dark or black materials?
Yes! Light-colored materials are more suitable for sublimation printing. At the same time, prints on dark fabrics don’t show full color. This is because sublimation inks are transparent, so they show up vibrant on light-colored materials. To print on darker materials, use a white base to make your designs appear brighter.
Are sublimation-printed products washable? How long do they last?
Yes, of course! They are highly washable and long-lasting after several washes. As the print is not pasted onto the material but infused into it as a gas, it becomes part of the material. So, it can last up to 100+ washes when properly cared for.
How much does it cost to get started with sublimation printing?
Various costs are included when calculating the total. These include printer, inks, paper, blanks, heat press, and other hidden supplies. With minimal setup, it can cost between $1500 and $3000. With premium settings for professionals, it can vary depending on the equipment you choose.
Do sublimation printers require maintenance?
Like all other printers, sublimation printers also require daily, weekly, or biweekly maintenance. It is always important that the inks do not clog the printhead. This can damage the printhead and lower the print quality.
