Sublimation transfer print vs direct print
Mar 17, 2022
Dye-sublimation (dye-sub) is a core method for printing onto fabric. There is a variety of equipment and inks for dye-sub graphics, ranging from entry level to industrial.
Heat is necessary for dye-sub printing because the inks sublimate—become gaseous—when they warm up and seep into the substrate. The sublimation process takes place directly on the cloth when using direct dye-sub. An external heat source is used to infuse a design onto sublimation paper, which is the initial step in the transfer dye-sub process. Despite their differences, the transfer and direct approaches have a lot in common.
Here, Digital Output explores the applications and situations when it’s advantageous to use dye-sub for fabric printing. We also highlight dye-sub printers and ink.
Benefits of Dye-Sub
Every printing technique has its uses, and every technology has advantages of its own. However, for longevity and color, dye-sub is the preferred technique for cloth printing.
While dye-sub typically uses only four colors, it produces a broad and vibrant color spectrum. The print supplier can more easily recreate and capture the subtleties of the image. According to PrinterEvolution's director of special projects, Michael Syverson, the depth of the image results from the ink or dye being infused directly into the substrate.
“This level of saturation produces superior output and a high-quality appearance. Sublimated fabrics can also be stretched into an infinite number of shapes and forms so the only limitation is the imagination. Other technologies will see cracking and crazing with stretching and folding,” he observes.
Dye-sub is appropriate for both long- and short-term applications.
“Both transfer and direct are good for short- and long-term indoor applications such as point of purchase (POP) and trade show displays.” suggests Tommy Martin, director, textile business development, Mimaki USA, Inc.
The two dye-sub methods each have unique benefits. Some print providers prefer transfer dye-sub, finding it easier to print directly on sublimation transfer paper rather than on fabric.
“The transfer process enables printing onto a wider variety of substrates, some of which are a challenge to print to directly—e.g. velour and most fabrics with less than 50 percent polyester composition,” explains Brent Moncrief, VP, sales and marketing, Durst Image Technology US, LLC.
Transfer doesn’t have the same UV resistance as some printing methods, so it’s not used as often for outdoor applications. However, if offers rich, deep color that makes it popular for many other uses and settings.
According to Epson product manager Catalina Frank, "dye-sub transfer is preferred for indoor signage and home decoration fabrics because of its high definition and color pop." Transfer, she continues, offers crisper pictures and shapes, making it perfect for applications in this market.
Coated fabrics are typically needed for direct dye-sub. "Direct dye-sub is intriguing because it reduces failure risk by avoiding the transfer step and allows for proof checking without transfer during the printing stage. Elevation According to Juan Kim, CEO of Valloy Incorporated, "paper and ink can also be saved."
Direct dye-sub is well-suited to outdoor applications, partly due to durability and partly because the process enables front-to-back bleed, which is ideal for banners and flags.
Selecting an appropriate ink increases the durability and longevity of directly-printed sublimation graphics.
“Whether you choice to print to sublimation paper and then sublimate to fabric or direct print to fabric, there are applications that are challenging for low-energy disperse dyes to meet. Applications that require outdoor—UV and wet—usage as well as high contact applications—rub fastness—can be a challenge for low-energy dyes,” explains Ted Zhi, textile marketing manager, DuPont Digital Printing.
Vendors anticipate an increase in demand for dye-sub. This is partially because new fabric applications are taking use of dye-sub graphics' richness and color. Apparel and soft signage are two of the most promising markets.
This is because there are more innovative materials available now for industrial textiles, performance clothing, and high fashion. More and more markets that are receptive to this technology are opening up along with the variety of materials available. Martin suggests that in order to cater to these new markets, advances in ink and equipment technology are underway.
