Dye Sublimation Printing Problems & Solutions Guide
Dye Sublimation Printing: Common Issues & Fixes
Q: What should I do if the image shows ghosting, blurring, or unclear edges?
Common Causes
- Material shifting during transfer: During flatbed pressing or calender transfer, if the transfer paper or fabric moves or slips, ghosting will occur.
- Surface contamination: Dust, fibers, or adhesive residue on the transfer paper, fabric, or heat platen can interfere with proper adhesion.
- Excessive material stretch or rebound: Elastic materials may stretch or rebound during pressing, causing image displacement.
- Excessive pressure: Too much pressure can cause the material to “grab” or shift on the platen.
- Press closing too fast: Especially on flat heat presses, a rapid closing action may momentarily lift the transfer paper, causing secondary contact before full bonding.
Solutions
- Secure all four corners of the transfer paper with high-temperature heat tape to prevent movement.
- Check and clean the heat platen, fabric, and transfer paper surface before pressing.
- Reduce pressing pressure to avoid excessive compression.
- Perform test prints on elastic materials and fine-tune parameters before production.
- Slow down the press closing speed if possible, or insert a protective sheet between fabric and platen.
Q: Sublimation is incomplete — colors look pale, grayish, or some areas fail to transfer. Why?
Common Causes
- Insufficient temperature or time: Heat energy is not enough for full dye sublimation.
- Uneven heat distribution: Long-term use may cause temperature variation across the heat platen.
- Material incompatibility: The coating or fabric composition may not be suitable for sublimation.
Solutions
- Regularly check and calibrate heat platen temperature.
- Ensure the material has a proper sublimation coating or adequate polyester content.
Q: Colors darken, shift, or water marks appear after heat pressing. Why?
Common Causes
- Moisture interference: Transfer paper, fabric, or padding absorbs moisture, which vaporizes during heating and disrupts color transfer.
- Overused padding: Old padding absorbs moisture repeatedly, increasing the risk of water marks.
- High ambient humidity: Common in rainy seasons or high-humidity regions.
Solutions
- Pre-heat fabrics to remove moisture before transfer.
- Store printed paper and materials in a dry environment.
- In high-humidity conditions, increase pre-heating time or replace moisture-absorbing padding.
Q: Some fabrics bubble, blister, or develop raised spots after heat pressing. Why?
Common Causes
- Special coating layers on fabric: Non-breathable coatings trap moisture or gas during heating.
- Excessive temperature or pressing time: Adhesive layers become over-activated.
Solutions
- Use segmented or patterned printing instead of full-coverage pressing.
- Lower the temperature and extend pressing time instead.
- Insert protective or isolation paper between fabric layers if necessary.
Q: Colors are correct, but print quality is unstable or inconsistent. What’s wrong?
Common Causes
- Aged or deformed padding: Uneven pressure leads to inconsistent transfer.
- Poor transfer paper quality: Unstable dye release affects color consistency.
- Inconsistent equipment pressure: Long-term use without calibration causes uneven results.
Solutions
- Regularly inspect and replace press padding.
- Use stable, high-quality transfer paper.
- Re-calibrate pressure settings to ensure uniform contact.

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