Sublimation Printing

Have you ever wondered why the sublimation pattern does not "float" on the surface like offset printing or silk screen printing? Why it does not have a thick film feel, but can still present clear and bright patterns? All this is due to the "sublimation + penetration" principle of sublimation ink. Today, we will explore the working principle of sublimation ink in depth to help you better understand and apply this technology.

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The core of thermal sublimation technology is to use heat energy to directly transform the dye from solid to gaseous state, and then penetrate into the fibers of the substrate. This process can be divided into the following key steps:

How It Works

1. Sublimation of Dyes
The dye in thermal sublimation ink changes directly from solid to gas at high temperature. This process is called sublimation and usually occurs between 180°C and 220°C. The sublimated dye gas can penetrate the fibers of the substrate.

2. Dye Penetration
The sublimated dye gas penetrates into the fibers of the substrate under the action of high temperature and pressure. This ensures the pattern is deeply embedded in the material, leading to high durability and strong adhesion.

3. Curing of Dye
When the substrate cools down, the dye gas that penetrates into the fiber condenses into a solid state, forming a strong, vibrant pattern. This process is called curing, which ensures the pattern remains bright and clear during long-term use.

Sublimation printing involves a physical change and chemical combination process.

Advantages of Thermal Sublimation Principle

1. No Fading: The pattern becomes part of the fiber and is not easy to wash off.

2. No Glue Feeling: The touch is soft and does not affect comfort during wear.

3. High-Definition Restoration: The technology can restore photo-quality pattern details.

4. Long-Lasting Pattern: Resistant to ultraviolet rays, wear, and provides high color fastness.

5. Environmentally Friendly and Clean: No solvents required, no waste liquid, and no odor during the printing process.

Common Questions about Sublimation Technology

Q: Why can sublimation technology only be used on polyester or coated materials?

A: This is because the sublimated dye molecules must penetrate the material itself. Polyester's molecular structure allows them to absorb and lock the dye at high temperatures. If the material is cotton or uncoated, the dye molecules remain on the surface, resulting in poor adhesion.

Tips

Four details to improve the "dye into fiber" effect:

• The ink concentration must be sufficient to ensure vibrant, not gray or false colors.
• The transfer paper must be of high quality, with balanced release rates for clearer patterns.
• Accurate temperature and time settings are crucial to avoid sticking or non-adhesion.
• The surface of the board/fabric needs to have a sublimation coating for improved color reproduction.

Advantages of Sublimation Ink

1. Bright Colors and High-Definition Pattern Restoration
Thermal sublimation ink uses high-purity dye molecules that provide high color density, a wide color gamut, smooth gradients, and clear lines, perfect for high-definition designs like portrait photos and illustrations. Ideal for customized gift manufacturers, e-commerce sellers, and design proofs.

2. Dries Quickly Without Nozzle Jam
High-quality thermal sublimation ink has fine particles and smooth flow, making it suitable for a variety of printheads, like Epson series. It dries quickly, reduces nozzle clogging, and extends the life of the printhead.

3. Low Cost, High Return
The ink usage is low, with 1L producing hundreds of A4 patterns. Compared to UV and DTF printing, sublimation printing has much lower consumable costs, making it perfect for mass customization. It also supports flexible equipment setups, making it an ideal solution for startups.

Summary

Sublimation technology offers high efficiency, flexibility, and quality, making it a powerful force in personalized customization. By transforming the dye from solid to gas and then penetrating the substrate fibers, it achieves durable, high-precision prints. Choosing sublimation technology can improve production efficiency and provide significant commercial value to businesses.

If you need test samples, recommended material combinations, or printing parameter guidance, please feel free to send us a private message. We will provide you with the most suitable matching plan and technical support.