Dye Sublimation: What Is It & How Does It Work?

If you’re wondering, “What is dye sublimation?” you’re more than likely interested in creating unique promotional items, such as printing on mugs, t-shirts, metals and more. But you may be unaware that sublimation printers are used to produce textiles for clothing, furniture, and signage as well. Dye-sublimation printing allows for vivid, sharp, and vibrant imagery – and stunning products. 

It’s also quite affordable if you aren’t planning on printing a large volume of products at a time. In fact, this form of printing is appreciated because it helps keep the budget low when producing a small number of items. Not to mention, dye sublimation creates considerably long-lasting prints, known for being extremely slow to fade.

This article goes beyond those quick answers to address what makes this form of printing special and how it expands what you can do. We comprehensively address this exciting technology via the following questions:

• What is Dye Sublimation?
• What is a Dye Sublimation Printer?
• What is Dye Sublimation Ink?
• What Materials Can Be Used in Dye Sublimation Printing?
• How Does a Dye Sublimation Printer Work?
• What are Different Types of Dye Sublimation Printers?

What is Dye Sublimation Printing?

There are primarily two different techniques for digital dye sublimation printing. Photo Dye sublimation is a printing process using a specially designed ribbon that holds solid inks. The printer heats the ink ribbon, causing it to sublimate – which means it skips the liquid form and transitions directly into a gaseous state embedding it into photographic paper. (Another example of the use of sublimation within the industry is freeze-drying). The three primary colors are applied to the photo paper and once the ink hits the media, it transitions from a gas back to solid, and a full-color image results. So that the ink does not smudge, the printer finishes by introducing a clear protective coating to the paper/substrate. While this technique has been around for decades, it is not as popular today and is almost exclusively used in high speed, on-site event photo printing (think wallet photos, 5x7s, 8x10s, etc).

The overwhelmingly more mainstream form of sublimation printing used today is generated using inkjet printers which “jet” liquid ink (forming the photo or image) onto a transfer paper. The paper is then heated (primarily, though not exclusively with a separate heat press) and the ink (image) is transferred into the polyester coated substrate (textile, ceramic, clothing, aluminum, etc.) producing your final printed product. Some higher-end, more industrial sublimation printers incorporate the “heat transferring” process/unit directly into the printing system, and “fix” the ink directly on the substrate. This is exclusive to textile or fabric sublimation systems. Most of today’s sublimation printers require that you purchase a separate heat press (platen) for individual piece transfers or a roll to roll calendar press for high volume textile production.

What is a Dye Sublimation Printer?

One way to understand a dye sublimation printer is to compare it to traditional inkjet printing. Here are three ways in which a dye sublimation machine differs from a standard inkjet printer’s process and capabilities:

1. Operation — While the printer hardware is essentially the same as a standard inkjet printer, your digital files are printed differently. First, you have to mirror your images to print them in reverse so they come out correctly on your final product after the heat transfer process. Also, because the ink is first printed to paper, then transferred to your substrate, you need to make sure that your have (or your equipment provider has) special color ICC profiles for accurate colors on whatever your printing on. 
2. Efficiency — Because there are a few steps in producing your final prints, its not as simple as just hitting the print button in your software to produce a final print. As mentioned above, you will need to remove the print from the printer, “marry” it with your final substrate (Chromaluxe, mugs, mouse pads, shirts, etc.) with heat tape, place it on the heat press, and then press. This can add a good amount of production time to the overall process.
3. Image Quality — Here, dye sublimation excels. Essentially, dye sublimation is similar to film, while inkjet printing is similar to video. The former creates an image similar to traditional photography, with a continually blended color range. A traditional inkjet printer is less seamless: you can see the primary color dots if the image is magnified. Because the image is “embedded” into the substrate, the print can take on may of the properties of what you are sublimating to yielding stunning results. This also adds to the durability of the image as the ink is not directly on the surface of the substrate. 

What is Dye Sublimation Ink?

Dye sublimation ink is utilized, along with intense pressure and heat, to print onto novelty items such as coasters, t-shirts, plaques, and mugs. It is important to note that sublimation ink is very different from the traditional dyes & pigments used in regular inkjet printers and therefore cannot be used to print (a finished image) on regular paper. Here are some key points on dye sublimation ink:

• It is generally less expensive than traditional aqueous and solvent ink.
• It is longer-lasting than traditional inks. You will not see the image wash off or peel off of the printed item.
• That said, sublimation ink can “settle” while not being used so if you don’t print everyday its good to either mildly shake your ink cartridges or agitate the ink inside the bottles/reservoirs.
• Dye sublimation ink is water-proof and most substrates can be washed without affecting the print.
• The high heat and coating make smudging nearly impossible.
• The accuracy is incredibly strong (given the specificity the vaporization allows over standard inkjet droplets).

What Materials Can Be Used in Dye Sublimation Printing?

These printers are not intended for typical workplace media such as printer paper, canvas, vinyl, labels, or envelopes. Rather, they are popular for printing onto coffee mugs, t-shirts, aluminum panels, textiles, and other novelty goods.

Substrates must be made of polyester or have a polyester coated surface. This technology does not function correctly with cotton or other natural fabrics. Rather than bonding with natural fibers as it does with synthetic ones, gaseous ink passes straight through natural textiles.

Mouse pads, floor mats, coasters, flip-flops, event wristbands, bathing suits, shower curtains, and athletic apparel are examples of media containing the necessary materials suited to dye sublimation printing. Beyond these broad promotional uses, the machines can be used to create photo prints or postcards via specially coated media, such as aluminum, tiles, wood, cards or paper.

Dye Sublimation Printer Process: How Does it Work?

Again, what is dye sublimation? While the above information allows a better understanding of the basics, let’s get a bit deeper with the notion of transfer paper. Transfer paper is commonly used with these printers, although direct-to-fabric printing is also possible. If you use transfer printing, the process is a bit more complex.

When you use a dye-sublimation printer to create projects via transfer:

• The transfer paper will be with the dye sub printer and sublimation ink. 
• A heat press is used to heat and press the image from the paper onto the substrate. 
• Sublimation occurs: the solid ink becomes a gas. 
• An incredible image starts to arise as the fibers of plastic material or synthetic fabric become permeated with the gas. 

It again helps to contrast a standard inkjet printer to a dye-sublimation printer (see above section). In the former, liquid ink within cartridges becomes solid via heat and air as it dries on the paper’s surface. The two-step dye sublimation printer process involves liquid ink being introduced to media, where it dries and becomes solid, followed by vaporization (sublimation, in this case) of the solid ink.

Example dye sublimation printing: cycling jerseys

Sublimated dye is often used to print onto cycling jerseys and similar athletic clothing. (As indicated above, this printer only works with synthetic substrates – so avoid cotton.)

Dye Sublimation Printing Process for Sportswear

What is dye sublimation printing for sportswear? Assuming you are using transfer printing, it is a four-step process:

Step #1. Create all the graphics.

You need to design graphics for each section of the jersey – the front and back, as well as the arms and cuffs. Combine the graphics into a master layout. The paper is printed from the master layout file.

Step #2. Print the dye sublimation ink onto the transfer paper.

You print the sublimation ink to a ream of transfer paper. The ink will rapidly form a solid.

Step #3. Utilize the roller for sublimation.

The transfer paper is positioned facing a bolt of synthetic fabric. The two items are directed into a sublimation roller.

Extreme heat (350-420 °F) and pressure are utilized within the roller to sublimate the ink. The ink that is on the transfer paper grows hot so fast that it skips the melting process and immediately evaporates. The vapor can also get deeper into the jersey because of the pores of the textile open in response to the heat.

The jersey’s pores shut once the heat is no longer present, capturing the sublimated ink. Within the jersey, the ink shifts back into a solid form. A permanent, full-color image has now been introduced to the fabric.

Step #4. Sew together the pieces.

At this point, you can throw out the transfer paper. Based on the parameters of your graphics, you should now have a bolt of fabric that includes all the components. Cut out each piece from the bolt and construct your finished jersey by sewing them together.

Types of Dye Sublimation Printers

You have options when it comes to purchasing a dye-sublimation printer. Some of the most robust and versatile models are the following, with highlighted notable characteristics: