What is Sublimation Printing?

Sublimation printing (dye sublimation) is a dye-transfer method in which a design is printed as a mirror image onto transfer paper with disperse-dye ink, and heat and pressure then turn the dye into vapor and drive it into polyester or other synthetic fibers. “Sublimation” is the change of a substance directly from solid to gas without passing through a liquid phase; the method is named after this property of disperse dyes (Kosloff, SGIA; e-PG Pathshala, Chapter 7). Because the dye is absorbed into the fiber and spreads within it (Kosloff), no separate print layer forms on the surface, as it does with plastisol or DTF. Turkish suppliers call it süblimasyon baskı.

How sublimation works

1. Printing: The design is printed as a mirror image on transfer paper with special disperse-dye ink (PRINTING United Alliance, 2016; SGIA Journal, 2020). Printing onto the paper can be done by digital inkjet, but also by screen, gravure and flexographic printing (Kosloff; SGIA Journal, 2020).
2. Transfer: The paper is brought into contact with the product, and heat and pressure are applied with a heat press or a heated-roller machine (Kosloff).
3. Migration: The dye turns to gas, is absorbed into the fiber and spreads within it. The paper is removed.

Sources give different values. According to SGIA’s older technical guide, sublimation inks sublimate in a range of about 177–230 °C (350–445 °F), and transfer time varies from about 5 to 40 seconds depending on print color, fabric and print thickness (Kosloff). The e-PG Pathshala course material gives transfer from paper to polyester as 380–410 °F (about 193–210 °C) and 30–90 seconds (Chapter 12). Temperature, pressure and time are linked: raising one may require lowering the other two. If the balance is wrong, the print may not transfer at all, transfer only partly, or smear (Kosloff). These ranges are a general frame; the real values are set by the dye, paper and fabric manufacturer’s data sheet. According to Kosloff, as there is no steaming or rinsing step after transfer, there is also no dimensional loss from shrinkage.

Which fibers suit it?

Some “sublimation” solutions marketed for cotton and blends use a special transfer medium; according to Impressions, these products aim to make sublimation possible on colored polyester and on cotton as well (Impressions, 2019; SGIA Journal, 2020). Because the working principle and durability vary by manufacturer, ask for an independent test report for these products.

Limits and points to watch

• A light-colored base is needed. The dye goes into the fiber and does not cover the base color: white and light tones come from the base, and on a dark base the colors do not show. In garments, sublimation has long been limited to white and light-colored polyester (Impressions, 2019); one ink manufacturer separately recommends transfer vinyl for dark fabric (Sawgrass).
• Approve color on the fabric. The color on the paper looks different from the final color formed on the fabric; the printer should match and test color on the final fabric (Kosloff).
• Heat needs care. Excessive hot pressing or ironing of disperse-dyed or printed textiles can cause color loss (e-PG Pathshala, Chapter 7). Write the care label accordingly.
• The fabric must be ready. The guide recommends removing residues such as size before transfer (Kosloff).

The method suits full-color designs with large areas on light-colored polyester; see the textile printing methods guide for scenarios. Outside textiles it is also applied to polyester-coated hard surfaces such as mugs (SGIA Journal, 2020). For sublimation ink suppliers, see the textile printing inks category, and for the shops that do the printing, the textile printing category.

Often confused with

• Transfer printing: This is an umbrella term. Dye transfer (sublimation on pieces, yardage transfer printing on rolls of fabric) and film transfer (DTF, flex, flock) are separate groups.
• DTF: In sublimation the dye goes into the fiber. In DTF a layer attached with adhesive stays on the surface of the product.
• Direct disperse-dye digital printing: The ink is printed directly on the fabric, not on paper, fixed with heat and washed if necessary (PRINTING United Alliance, 2016). In sublimation transfer, the image is transferred from paper.

Frequently asked questions

Can sublimation printing be done on a cotton T-shirt?

Classic sublimation gives no result on cotton: cotton is not among the fibers that disperse dyes dye easily. Epson recommends 100% polyester for best results and does not guarantee quality or color accuracy on cotton and cotton-polyester blends. On a cotton T-shirt, DTG, DTF or screen printing is used. For a comparison, see the textile printing methods guide.

Can dark polyester T-shirts be sublimated?

Not with classic sublimation: the dye does not cover the base color, so colors do not show on a dark base. Special transfer media are marketed for colored bases (Impressions, 2019); ask for an independent test report for them. On a dark base, methods such as DTF, screen printing or flex are also considered.

Does a sublimation print come off in the wash?

Because the dye goes into the fiber, there is no separate film on the surface; durability is judged by color fastness tests. A fixed number of washes cannot honestly be quoted. Have color change and staining after washing tested to a standard method such as ISO 105-C06, and write the heat and ironing conditions into the specification as well.