Everything you need to know about sublimation

Sublimation is a personalisation technique that has gained popularity for its ability to produce high-quality prints on a wide range of materials. This unique process involves transforming a special ink into a gas under the effect of heat, allowing direct printing onto the product. This method is particularly valued for its precision and durability, delivering results that do not fade and withstand everyday wear and tear.

The main advantage of sublimation lies in its versatility. It is ideal for a wide range of products, from clothing and fashion accessories to promotional and decorative items. An excellent example of this versatility is illustrated by how to personalise a lanyard, where sublimation makes it possible to create unique and attractive designs, with vibrant colours and great precision.

However, sublimation also has its limitations. It requires specific materials, generally synthetic fabrics such as polyester, and cannot be applied to all types of surfaces. In addition, although the print quality is superior, the initial cost and equipment requirements can be higher compared to other personalisation methods.

In this article, we will take an in-depth look at the sublimation technique, its applications, its advantages and its disadvantages. We will also cover the types of products that can be sublimated, providing a complete overview of this innovative personalisation method.

How does sublimation work?

Sublimation is a fascinating printing process that uses a unique physical phenomenon. To understand how it transforms a design into a vivid and long-lasting print, let’s explore its steps and the required conditions.

Sublimation: a unique physical phenomenon

Sublimation is the transition of a substance directly from a solid state to a gaseous state, without passing through the liquid state. This phenomenon is at the heart of the sublimation printing technique. A common natural example of sublimation is snow that evaporates without melting.

Special inks: a key role

For sublimation, special inks known as sublimation inks are used. These inks have the unique ability to change state under the effect of heat and pressure, moving directly from solid to gas.

The right substrate: polyester or polyester coating

The substrate to be printed must be made of polyester or coated with polyester. This synthetic fibre is essential because it effectively absorbs sublimation inks. Other materials, such as cotton, are not compatible with this technique.

The stages of the sublimation process

1. Creating the artwork : The design is created using graphic design software, respecting the required dimensions and resolution. The artwork is mirrored to ensure correct printing.
2. Printing onto transfer paper : The design is printed onto a special transfer paper, designed not to absorb the inks but to transfer them efficiently.
3. Positioning the paper on the substrate : The transfer paper is placed on the substrate and secured with heat-resistant tape to prevent any movement during transfer.
4. Heat press stage : The substrate and paper are placed in a heat press. The temperature and pressing time are adjusted according to the substrate. The inks vaporise and penetrate the polyester fibres, creating a durable print.
5. Removing the transfer paper : After transfer, the paper is removed, revealing a high-quality print on the substrate.

By following these steps, sublimation enables the creation of high-quality, durable prints with vibrant colours, ideal for lanyards and other personalised products.

Sublimation equipment

To achieve high-quality sublimation, several specific pieces of equipment are required:

1. Inkjet printer for sublimation : These printers are equipped with cartridges containing special inks. These inks, made of sublimatable dyes, vaporise under the effect of heat.
2. Transfer paper : This special paper plays a crucial role in the sublimation process. It is designed to retain the inks on its surface without absorbing them, making transfer to the substrate easier.
3. Heat press : This equipment applies the heat and pressure required to activate the sublimation process. The press ensures that the inks turn into gas and penetrate the substrate.
4. Sublimation substrates : Materials suitable for sublimation must be made of polyester or polymer-based materials. These materials have the ability to open under heat and close again when cooling, permanently trapping the inks.

Successful sublimation depends on specific conditions of temperature, pressure and time, which vary according to the type of substrate.

Here is a summary table of the optimal conditions for different substrates:

The different sublimation techniques

Sublimation, a creative and technical process, is available in several methods, each suited to specific needs.

Direct Sublimation : This technique involves printing the design directly onto the substrate. It is fast and cost-effective, although the result is less precise than other methods. It is particularly suitable for flexible substrates such as t-shirts or banners.

Thermal Sublimation : Here, the design is printed onto a plastic film and then transferred to the substrate using heat. This method is known for its high-quality finish, with vibrant colours and fine details, making it ideal for rigid substrates such as mugs or phone cases.

Transfer Sublimation : This approach involves printing onto transfer paper, followed by cutting and application onto the substrate. It offers great versatility and is easy to carry out, well suited to a variety of substrates such as wallets or bags.

Each of these techniques has its own advantages and applications, allowing great creativity in product personalisation.

What are the advantages of sublimation?

Sublimation stands out from other printing techniques such as screen printing, transfer or embroidery thanks to its many advantages. Let’s see why sublimation is an excellent choice for your lanyards.

Superior print quality

Sublimation delivers exceptional print quality. Colours are vibrant, accurate and long-lasting. Unlike screen printing, which applies a layer of ink onto the fabric, sublimation infuses the fabric with inks, ensuring better colour fastness and higher pattern resolution.

Accurate reproduction of complex designs

With sublimation, you can reproduce complex designs, colour gradients or photographs with great precision. This technique is ideal for sophisticated logos or detailed images, offering unlimited creative freedom.

Fabric comfort preserved

Sublimation does not alter the feel of the fabric. The result is a soft and comfortable fabric, without the stiffness or sticky feel sometimes found with other techniques such as transfer or embroidery.

Resistance and durability

Prints created using sublimation are resistant to washing, friction, UV rays and chemicals. Your lanyard retains its brightness and shape over time, without cracking, distortion or fraying.

Environmental and economic benefits

Sublimation is an eco-friendly technique, producing no waste or solvents. Water-based inks are free from harmful substances, respecting the environment and quality standards. In addition, this technique is cost-effective, with no setup fees or minimum order quantity, allowing you to order the exact quantity you need without extra costs.

Sublimation offers superior print quality, high precision in design reproduction, outstanding wearing comfort, exceptional durability, and significant environmental and economic advantages.

What are the disadvantages of sublimation?

Although sublimation is a printing technique renowned for its many advantages, it also has certain disadvantages and limitations. Let’s examine these aspects to better understand this method and consider suitable solutions.

Requirement for a specific substrate

Sublimation requires a polyester substrate or one with a polyester coating. This means you cannot use this technique on materials such as cotton, linen, leather or wood. For these substrates, other methods such as screen printing or transfer are more appropriate.

Incompatibility with dark colours

Sublimation inks are transparent and cannot cover dark or black substrate colours. If you want to print on a black lanyard, sublimation is not a viable option. You will need to choose a light-coloured substrate or another printing technique.

Potential unwanted effects

Sublimation can cause unwanted effects such as ghosting (blurred or double images), bleeding (colour smudging or overflow) or gassing out (stains or white areas). These issues generally occur due to incorrect press settings, transfer paper movement or excessive humidity. It is crucial to follow the press parameters and use protective paper to avoid these problems.

Specific equipment and technical expertise

Sublimation requires specialised equipment: an inkjet printer with sublimation inks, suitable transfer paper and a professional heat press. In addition, technical mastery of press settings is essential to achieve optimal results. This involves an initial investment and a learning curve for those new to this technique.

Although sublimation is a high-quality printing method, it requires a specific substrate, is not suitable for dark colours, can present technical challenges and requires specialised equipment. It is important to weigh these disadvantages against the advantages to determine whether sublimation is the right technique for your project.

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• Why personalise a lanyard?