What is Dye Sublimation?

We discuss here the process of image transfer, where a transfer paper is printed  “mirrored”  using dye sublimation ink and an ink jet printer. The image is then transferred to a substrate using heat and pressure provided by a suitable Heat Press.

Dye Sublimation Ink.

 The term sublimation refers to the property of sublimation ink to change state from a solid to a gas when subject to a high temperature. The gas molecules bond to the substrate producing a mirror image of the original image printed onto the transfer paper. It therefore follows that the first image printed on the transfer paper should be a mirror image of the end result required.

 Transfer Paper.

 The transfer paper is normally coated with a barrier layer, this is to prevent the ink or dye sublimating into the transfer paper and so affecting the quality of the image transferred to the substrate.  The dye or ink is not chemically bonded to the transfer paper, and so must be allowed to dry properly and should be handled with care. Do not touch the printed surface and avoid contamination with moisture or dust. Once transferred with heat and pressure the image is permanently bonded to the substrate.

 Substrates.

 Dye Sublimation inks will generally only bond to synthetic materials such as polyesters, nylons, urethanes and so on. Anything else, such as wood, metal, glass, cardboard, particle boards and ceramics need to be coated first. Virtually anything can be coated and printed to provided that the base material can withstand the temperature and pressure needed to set the sublimated image. Synthetics such as polyester t-shirts, carpet and other polymer fabrics do not need any treatment prior to transfer.

 The Coating.

 There are various coatings available, including water based, resin based, and powder - providing the needed polyester / polyurethane base needed for the dye or ink to bond with. Glass would normally be coated with a clear lacquer first, followed by a thin white coat, allowing the image to show through the glass, as used in chopping boards for kitchens or clock faces, artwork and so on. Pre-coated "blanks" i.e. mugs, plates, metals and so on are readily available.

Heat and Pressure.

 Heat and pressure are needed for the image transfer process – Heat to make the ink sublimate to a gas and pressure to keep the transfer paper and substrate pressed closely together. Any gap or void will result in a blurred or fuzzy image or no transfer at all. A blurred or washed out image can also result from moisture. More on problems with moisture.