Sublimation

Sublimation printing, also known as dye sublimation printing, is one of the most common ways to print images onto synthetic fabrics and materials. The digital printing is crisp, clear, colourful and won’t fade, crack or peel.

Sublimation printing is a very specialized printing technique that requires very specialized equipment. The design is printed onto a large ream of transfer paper using specialized sublimation inks using a specialized digital printer. The inks are liquid within the cartridge but are formulated to become solids very quickly once printed. Once the transfer paper has been printed with the design, the roll of transfer paper is aligned with a bolt of polyester fabric so that the printed side is facing the fabric.

The transfer paper and the fabric are then fed into a heated roller. The sublimation process takes place within this heated roller. Through a combination of pressure and heat (between 350 and 420 degrees Fahrenheit), the solid sublimation ink on the transfer paper becomes so hot that it evaporates and diffuses before it even has a chance to melt.

This intense heat also opens the pores of the polyester fabric, allowing the ink vapour to work its way deep into the fabric. Once the heat has been removed, the pores of the fabric snap closed, capturing the ink vapours. The ink then quickly reverts to its solid state within the fabric. As a result, the material has been permanently dyed with a full colour, high resolution image. It’s then cut and sewn together, and you have your finished garment.

If you are looking for a truly fully customizable solution right down to the smallest detail, this is the right choice. You can do unlimited colours, logos, and placements on your garment all at a flat rate price. This is the top choice for many teams that require several logos on their garments. Many suppliers will also allow individual customization included in the garment cost. This is an ideal solution for sports teams and is a very popular choice for all athletic apparel. Sublimation is also a great option for some unique products like neck gaiters, scarves, flags, pop-up canopies, socks, lanyards and so much more.

If you have a team, are looking for a creative customer give away or are looking for a fresh new look for your company polos, contact us today. We will make it happen.

This process only works on 100% polyester. Sublimation printing does not work on natural textiles like cotton because the vaporized ink can pass through the fibres without bonding to them.

The cost of this very specialized equipment is high so it’s not readily available at most decorators and will likely need to be outsourced. Because of this, the time it takes to produce these garments is usually 4 to 6 weeks with many suppliers before you will get your garments. You will also have to order a minimum number of pieces.

Artwork quality can also be another challenge. It must be vector artwork and will need to be very high quality. There are no exceptions. If you don’t know whether you have a vector logo, contact us and we can tell you right away. If it’s not a vector our team can convert it into a vector for a small one-time fee.

You’ve got your new custom printed apparel & you love it so much you want it to last a long
time. Here’s our recommended garment care instructions to prolong the life of your printed
apparel.

We recommend turning the garment inside out and washing on cold cycle using a mild
detergent and no fabric softener. Heat can cause fading & shrinkage of the garment & will
degrade the print faster. We also recommend:

– Do not dry clean
– Hanging to dry
– Wash with like colors/materials.
– Do not bleach.
– Do not iron the print.

What Is Dye Sublimation Printing?

Dye sublimation printing is an advanced printing method that uses heat to transfer dye directly into a polyester material or polymer-coated surface. Unlike traditional printing methods where ink sits on top of a surface, sublimation permanently bonds the design into the material, creating vibrant, durable, and long-lasting prints.

This process is commonly used for custom apparel, promotional products, signage,
personalized gifts, and specialty items.

Requirements for Dye Sublimation Printing

1

Sublimation Printer

A dedicated sublimation printer is required to produce high-quality transfers.
These printers are designed to work with sublimation inks and provide accurate
colour reproduction.

A quality sublimation printer should offer:

  • High-resolution printing
  • Reliable ink delivery
  • Accurate colour output
  • Compatibility with sublimation ink systems
  • Support for professional colour profiles

2

Sublimation Ink

Special dye sublimation inks are essential for this process. When heated,
sublimation ink changes from a solid state directly into a gas. The dye then
penetrates polyester fibres or polymer coatings and becomes permanently embedded
into the surface.

Important:
Standard printer inks cannot be used for sublimation printing.

3

Sublimation Transfer Paper

Sublimation paper is specially coated to hold printed dye before transferring it
to the final product.

High-quality transfer paper helps achieve:

  • Sharper images
  • Brighter colours
  • Better ink release
  • More consistent results

4

Suitable Materials

Dye sublimation works best on materials containing polyester or surfaces with
a polymer coating.

Ideal Fabric Materials
  • 100% polyester garments
  • Polyester blends with a high polyester content
  • Sportswear
  • Flags and banners
  • Performance apparel
Suitable Hard Products
  • Ceramic mugs
  • Aluminum panels
  • Tumblers
  • Phone cases
  • Keychains
  • Photo panels
  • Polymer-coated gift items

Note:
Natural fabrics such as cotton do not accept sublimation ink unless specially treated.

5

Heat Press Equipment

A heat press is used to apply the required combination of temperature, pressure,
and time.

Different products may require:

  • Flat heat presses for clothing and flat products
  • Mug presses for drinkware
  • Cap presses for hats
  • Large-format presses for fabric production
Temperature
180–210°C
356–410°F
Time
30–90 seconds
Pressure
Medium

Exact settings vary depending on the material and manufacturer recommendations.

6

Design Software

Artwork is created and prepared using professional design software.

Common Software
  • Adobe Photoshop
  • Adobe Illustrator
  • CorelDRAW
Design Preparation
  • Creating high-resolution artwork
  • Adjusting colours
  • Sizing designs correctly
  • Mirroring artwork before printing
  • Preparing files for the specific product

The Dye Sublimation Printing Process

1

Design Creation

The artwork is created digitally and prepared for printing. The design is adjusted
to the correct size, resolution, and colour settings for the final product.

2

Printing the Transfer

The design is printed onto sublimation transfer paper using sublimation ink.

The printed image may appear lighter or less vibrant at this stage. The final colours
appear after the heat transfer process.

3

Preparing the Product

The item being printed is cleaned and positioned carefully.

  • Remove dust and lint
  • Align the transfer paper
  • Secure the design with heat-resistant tape
  • Ensure the surface is ready for pressing

4

Heat Transfer

The printed transfer paper is placed onto the product and pressed using heat
and pressure.

  1. Sublimation ink turns from a solid into a gas.
  2. The gas penetrates the polyester fibres or polymer coating.
  3. The dye bonds permanently with the material.
  4. The image becomes part of the product surface.

5

Finishing and Quality Inspection

After pressing, the transfer paper is removed and the product is inspected.

A finished sublimation print provides:

  • Bright, detailed images
  • Smooth surface finish
  • Excellent durability
  • Resistance to washing and fading

Benefits of Dye Sublimation Printing

Vibrant Full-Colour Results

Sublimation allows for detailed photographic images, gradients, and unlimited
colour combinations.

Long-Lasting Prints

Because the dye becomes part of the material, prints are highly resistant to
cracking, peeling, and fading.

No Minimum Order Requirements

Sublimation can be cost-effective for both single items and larger production runs.

Ideal for Custom Products

  • Personalized clothing
  • Team uniforms
  • Corporate merchandise
  • Promotional products
  • Custom gifts

Limitations of Dye Sublimation

  • Best results require polyester or polymer-coated materials
  • Most applications work best on white or light-coloured products
  • White ink is not available in standard sublimation printing
  • Cotton requires special treatment or alternative printing methods

Getting Started with Dye Sublimation Printing

A basic sublimation setup includes:

  • Sublimation printer
  • Sublimation inks
  • Transfer paper
  • Heat press equipment
  • Design software
  • Heat-resistant tape
  • Protective sheets
  • Sublimation-ready products

With the right equipment and materials, dye sublimation provides a reliable way to create
professional-quality custom products with vibrant, permanent designs.

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