How it works
Sublimation ink contains disperse dyes. The design is printed mirrored on sublimation paper. Under heat and pressure the dye turns into a gas and enters the polyester (or polyester coating), which opens up when hot. When it cools, the dye is locked inside the material. Nothing sits on top, so there is no feel and the print cannot crack or peel.
Two production routes
- Transfer sublimation – print on paper, then transfer with a flat press (garments, hard goods) or a rotary calender (fabric rolls, sportswear panels).
- Direct sublimation – print straight onto polyester fabric, then fix through a calender or oven. Faster for flags and soft signage; needs fabric made for direct printing.
Typical transfer settings
| Item | Temperature | Time | Pressure |
|---|---|---|---|
| Polyester garments | 190–205°C | 45–60 s | Medium |
| Rotary calender (rolls) | About 200–210°C | Set by drum speed, typically 30–60 s contact | Blanket tension |
| Mugs (mug press) | 180–200°C | About 3–5 min | Medium |
| Coated metal / MDF / tiles | As per blank supplier | As per blank supplier | Light to medium |
These are starting points. Each paper, ink and blank has its own sheet; test first.
Materials
- White or light-coloured polyester; the higher the polyester share, the brighter the result (aim for 65%+, best 100%).
- Polymer-coated mugs, bottles, plates, metal sheets, MDF, tiles, mouse pads, puzzles.
- Not cotton, not dark fabric. Sublimation cannot print white.
Strengths
- Vibrant colour and photo quality.
- Zero hand feel, breathable, ideal for sportswear.
- All-over and edge-to-edge printing.
- Low running cost.
Limits
- Polyester and coated items only.
- Light colours only.
- Colours look dull on screen before pressing; judge colour only after transfer.
Common faults
| Fault | Usual cause |
|---|---|
| Ghosting / double image | Paper moved when opening the press; tape the paper |
| Dull, washed-out colour | Low temperature or time, low polyester content, or wrong ICC profile |
| Blurry edges | Moisture in paper or fabric; pre-press the blank, store paper dry |
| Press box marks or shine on fabric | Too much pressure or heat; use a pressing pillow and cover sheet |
| Brown or yellow scorch | Too hot or too long |
Videos and references
External videos are from other companies and may show different machines. Where they differ, follow the TrueDot steps above.