Sublimation Printing: How It Works, Pros, and Cons

Discover how the sublimation printing process works and how it compares to other printing methods like screen printing and direct-to-garment printing.

Dry ice is only fun because it sublimates. Instead of melting into a puddle, this solid form of carbon dioxide turns into a thick, smoggy cloud when exposed to temperatures above –109 degrees Fahrenheit. Dry ice sublimation creates the heavy smoke that rolls out of certain fog machines and gives Halloween punch bowls their signature witches’ brew aesthetic.

Sublimation is a physical process in which matter passes directly from a solid to a gaseous state. It happens under certain atmospheric conditions—different elements require different temperature and pressure conditions to sublimate.

This is the science that makes sublimation printing possible. This technique uses heat and pressure to trigger a dye sublimation process and fuse images onto new materials like t-shirts, mugs, and coasters.

Luckily, you don’t need a master’s in physics to create custom sublimation transfers. Sublimation printing is a simple way to create durable designs with vibrant colors. Learn about how dye sublimation printing works and how it differs from traditional printing methods.

What is sublimation printing?

Sublimation printing is an image transfer technique. The process involves creating a printed sublimation design and using a heat press to move the image from one surface to another. Its distinguishing characteristic is the method of transfer: The dye is converted from a solid to a gas, fusing with the material. Sublimation designs can be printed on a range of materials including fabric, ceramic, and metal.

You can use design tools like Canva or Adobe Illustrator to create your sublimation printing designs. Make sure to use high-resolution (300 dpi or greater) images for printing. Many print-on-demand companies can accommodate sublimation printing.

How sublimation printing works

For the sublimation printing process, you need special ink; a dye sublimation printer; and sublimation transfer paper, a special transfer paper with an absorbent chemical coating. Dye sublimation printers read digital files just like standard printers and print ink onto sublimation paper. Once the printed design is complete, printmakers use a heat press to transfer the design to a new surface. Sublimation heat presses force the solid ink into a gaseous state. Once in this form, it permeates and fuses with the printing substrate (the material to be printed on).

The sublimation printing process yields uniquely durable products. Other printing methods, such as screen printing or direct-to-garment (DTG) printing, create designs by transferring a thin layer of ink onto an item’s surface. These designs may crack or fade over time. Sublimation prints will never crack because the design actually becomes part of the fabric.

The dye sublimation process can transfer designs to a variety of items, including t-shirts, coffee mugs, and mouse pads, but it’s only compatible with polymer-coated or polyester materials. For sublimation shirt printing, you can use 100% polyester t-shirts or poly-cotton blends. For ceramic or metal objects, you’ll need to prepare your product with a polymer coating. These pre-treated products are called sublimation blanks.

Pros and cons of sublimation printing

Sublimation printing is a fast, cost-effective way to create customized products, though there are specific drawbacks. These are some of the key aspects to consider:

Pros of sublimation printing

• Fast. The sublimation printing process uses machine-printed transfer sheets to create designs, and it’s considerably faster than manual printing methods.

• Efficient. Unlike traditional printing methods, which often apply ink to the entire surface of a stencil, sublimation printing only applies ink to necessary parts of the design. This cuts down on wasted ink.

• Durable. With sublimation printing, dye permeates and fuses with the fabric rather than sitting on the surface. Sublimation prints won’t crack or flake over time.

• Prints on hard or soft surfaces. With the correct tools and materials, sublimation printing can be used to transfer designs to hard surfaces, such as metal and ceramic, in addition to fabrics.

• Renders detailed, colorful designs. Thanks to the printing process and CMYK color processing, this method can create intricate designs with vibrant colors.

Cons of sublimation printing

• Limited material compatibility. This method can only print designs on polyester fabric, polyester blends, or poly-coated materials. Blended fabrics must be at least two-thirds polyester or treated with a polymer coating to absorb sublimation ink.

• Not suited for dark fabrics. Sublimation dyes are semi-transparent. Designs may not be visible against a dark background such as a black shirt.

• UV sensitivity. Sublimation ink is UV sensitive—printed designs can fade over time if exposed to direct sunlight.

• Susceptible to white creasing. Seams, creases, and accidental fabric folds can result in a printing error known as white creasing. If this occurs, portions of your substrate will be left undyed.

• Cannot print white. CMYK color processing does not include white ink. Sublimation printers leave white elements blank. After the heat transfer, these undyed areas will be the same color as the garment or background.

Sublimation vs. screen printing

Screen printing is a traditional printmaking technique. The process involves creating a stencil or template on a permeable material. To make a print, press ink through the screen material. The template blocks portions of the transfer, and the final product is a negative (or inverse) of the starting image. Once the screen template has been created, it can be used numerous times to print copies of the design.

Sublimation and screen printing have a few key differences:

• Time and expense. Creating a screen printing template is more labor-intensive than printing a design on sublimation paper. The complicated setup makes screen printing more expensive than sublimation printing at the beginning, but it may be cost-effective for bulk orders.

• Design style. Screen printing is well-suited for bold graphic designs. Sublimation printing can render intricate designs with more detail.

• Color range. With screen printing, each additional color requires creating a new printing template, so creating multi-colored images can be expensive and time-consuming. A sublimation print can include as many colors as you like, but semi-transparent sublimation inks may be less saturated than screen-printing ink.

• Durability. With screen printing, printed designs sit on the surface of the fabric and may crack over time. The dye sublimation process creates durable designs that infuse with the surface material.

• Material compatibility. Screen printing is well-suited to printing on natural materials, including cotton and linen. Sublimation printing requires polyester fabrics or polymer-treated materials.

Sublimation vs. DTG

Direct-to-garment (DTG) printing uses specialized printers to print designs directly onto the final substrate. DTG printing requires minimal setup. There’s no need to make a template—DTG printers read digital files and spray water-based ink to create prints. This method can create photorealistic full-color images.

Both sublimation and DTG can render high-quality, detailed images, but they have a few key differences:

• Time and expense. Even though the setup is quick, the DTG process is slower than sublimation printing. It’s also pricier. DTG printers are more expensive than sublimation printers, and the cost per item is typically higher.

• Color range. DTG and sublimation printing can both print multi-color images in a wide range of hues. Unlike sublimation printers, DTG devices can accept both CMYK and RGB files and can print with white ink.;

• Durability. DTG printing creates a thin layer of ink on the surface of printed materials, so designs may be subject to cracking or flaking after extended wear. Sublimation shirt prints are less likely to crack.

• Material compatibility. DTG printing performs best on cotton fabrics. This technique is only for printing on textiles. For other materials, such as ceramic or metal, you can use a similar process known as direct to film (DTF).

Sublimation printing FAQ

Can any printer do sublimation?

No. Printing a sublimation design requires a special dye sublimation printer or a converted printer. Standard inkjet printers aren’t compatible with sublimation ink.

Is sublimation printing better than vinyl?

The best printing method depends on your individual needs. Sublimation transfers are typically more durable than their vinyl counterparts, which may begin to crack or peel with frequent use or excess heat exposure. Vinyl printing, however, is compatible with a wider range of materials, including cotton and linen.

Is sublimation printing better than vinyl?

Sublimation printing requires a sublimation printer, sublimation ink, special transfer paper, and a heat press. Some printers also use parchment paper to keep the press clean during the heat transfer process.