What is dye sublimation?
Dye sublimation is a digital printing technique for fabrics that uses heat to turn ink into gas, which then penetrates and permanently dyes polyester fabric fibers. Unlike traditional methods (screen printing) that just sit on top of the fabric, sublimation becomes part of the material itself, resulting in a zero-feel (no raised ink), durable, and fully-breathable garment.
Steps of the dye sublimation process:
1. High-resolution, full-color art designs are printed onto specialized, high-release transfer paper.
2. The paper is placed on a white polyester fabric and fed into a heat press at 350-400°F.
3. The ink turns from solid to gas, opening the fabric pores and bonding at the molecular level.
4. The fabric cools and traps the ink inside, resulting in a permanent, vivid image that will not crack, peel, fade or wash out.
What are the Key benefits of Dye Sublimation for apparel?
- Unlimited Colors: Dye sublimation is ideal for intricate, photographic, or full-color designs. You can use unlimited colors without extra cost. Screen printing requires an extra cost for each color you add.
- Full Coverage: Unlike screen printing, you can print from seam to seam, including sleeves, collar, and back. No spots are left blank.
- High Durability: Because the ink is bonded inside the fibers, it will not fade, crack, or peel, even after countless washes.
- Optimal Comfort: The breathable fabric retains its original soft feel and moisture-wicking properties, making it ideal for performance wear.
- Eco-Friendly: The process uses water-based, non-toxic inks and produces minimal waste.
What are the Limitations of Dye Sublimation Printing?
- Dye sub only works on polyester, polymer-coated, or high-polyester blend fabrics. It does not work on cotton.
- Sublimation works best on white or light-colored fabrics. Because the ink is transparent, it cannot be used to print lighter colors onto dark fabrics.
- All-over printing may result in minor, unavoidable white "ghost" creases under the arms or near seams.
What Are the Best use cases For Dye Sublimation?
Dye sublimation is the best choice if you want vibrant, full-color, all-over designs on high-performance athletic apparel that will last for years without cracking or peeling, all while remaining totally breathable and comfortable. Here are some ideas for products:
- Athletic Uniforms: Basketball, soccer, football, and running jerseys (lightweight and breathable)
- Corporate Branding: Branded t-shirts, polo shirts, and event apparel
- Merchandise: High-resolution graphic t-shirts
- Promotional Items: Custom fishing shirts, hoodies, and activewear
How Do I Design for Dye Sublimation?
Ask us for a free design template. It's easy to use, fun and the design possibilities are endless.
Need design help or stock patterns? We can design for you as well if needed.