A GREAT WAY TO DECORATE OBJECTS; FROM T-SHIRTS TO THE SIDES OF BUILDING

Sublimation transfers have changed the way we decorate myriad products form garments to license plates. Although sublimation links have been around for decades, the new digital ink jet technologies have been successful in bringing the process to mainstream America. I began using sublimation transfers over 20 years ago but you either had to screen print sublimation inks onto paper or job out your custom transfers to an offset printer. And in those days we were limited to substrates that we could heat apply these new transfers onto. In fact, to apply a sublimation transfer to a garment, we had to use a polyester spray treatment and the hard goods like license plates and sign blanks were hard to find. However, in today’s market, blank goods for sublimation are abundant and the following information will help introduce you to the many exciting decoration ideas that sublimation brings to the table.

SYNOPSIS OF SUBLIMATION

Now, with a small investment in a computer, ink jet printer, heat press and sublimation supplies you’re in business! You may choose to source all hardware items directly from an office supply house, but I suggest that you buy a complete package from one of the many sublimation dealers in our industry. Choose a company to work with that will offer training and continuing support, this is a small industry and the major players are easy to find. Many sublimation supply companies sell their sublimation packages almost exclusively via the internet while others choose to meet and sell to customers at industry trade shows. Whichever route you choose, do your homework understand the process and define who the players are before you buy. Ask these sublimation suppliers for references and don’t be afraid to network around and ask other companies who they recommend.

Like any process there is a wide range of variables that need to be understood in order to control color reproduction and design clarity. Variables include the scanned image resolution, the graphics software used, the type of printer, substrate quality, paper selection and the heat transfer machine. This is probably the best reason to go with an experienced supplier who can help you when you have technical questions. Producing sublimation transfers is an easy process to master with the right training and attention to detail on your part.

Technically speaking, sublimation is defined as “To cause [a solid or gas] to change state without becoming liquid”. The sublimation process is used to imprint objects by applying dyes that turn from a solid to a gas when heated. In order for the process to succeed, the substrate to be printed needs to process a high level or polyester, or have a polyester surface applied to accept the sublimation ink when heated. To transfer the sublimated image from the transfer paper to the substrate, the paper is placed in contact with the substrate and heated to the appropriate temperature in the range of 385 to 425 degrees Fahrenheit, depending on you on your ink manufacturer’s guidelines. When heated properly the molecules of the polyester coating (or substrate) open up and accept the sublimation gas into the open pores trapping the ink in the polyester molecules. When the polyester coating cools, it encapsulates the ink.

Brilliant designs are being transferred to objects such as mouse pads, license plates, coasters, key chains, signs, glass and ceramic tiles. Sublimation is truly the best thing to happen in substrate decoration and the personalized gift and awards market in years. Other industries across the country are finding that the versatility sublimation transfer decoration offers can be applied to a wide range of products from outdoor sign murals on upscale buildings. Sublimation is proving to be a versatile, mainstream decoration process.

SUBLIMATION ON GARMENTS

The flexibility that sublimation inks have given garment decorators is a new and exciting process. There are a variety of polyester garments specifically for sublimation transfer embellishment. Many screen printers choose sublimation transfers as an option for short runs to avoid screen printing small orders. However the higher cost of sublimatable garments still leaves the majority of longer run jobs to screen printing. This will change in time as the polyester garments come down in price and as better manufacturing processes for these garments becomes available.

Ask your garment supplier if he carries a line of sublimatable garments. There are a number of quality garment manufacturers that offer a line of garments with a high polyester content, made specifically for sublimation transfers. One of the most common T-shirts used in sublimation printing today is the Hanes Soft Link Tee. This is a unique T-shirt that uses a polyester sheath around the cotton inner yarn. This special yarn combines the soft feel of cotton while providing the polyester content needed for the sublimation process.

As outlined above, the substrate must have a polyester coating applied to the transfer side of it in order for the image to be heat transferred properly. There are a number of manufacturers who specialize in coating mugs, ceramic tiles, glass cutting boards, jewelry and more with their own hard coating polyester. Adding any or all of these products to your current product offering is an exciting possibility.

HEAT TRANSFER MACHINES

You may be surprised to know that you can use a clamshell style heat press to transfer sublimation transfers to plaques, tiles and other flat substrates. But the clamshell machine must have an adjustable gap setting to allow for these thick threedimensional
items. Another helpful feature for a clamshell heat press is to have a “floating lower” platen to selfadjust to parallel when the upper heat element comes in contact with the tile. A fixed lower can cause a pinch point where the heat element comes in contact with the tile or plaque causing the substrate and the transfer to slip out of alignment with each other. Because of this fact, many sublimation decorators prefer the swing away heat transfer machines that allow the heat element to come down directly parallel on top of the substrate and transfer.

Large format heat transfer machines with an oversized 30-inch-by-40-inch heat press are suitable for working with large tile murals and glass products. The large, lower machine platen is ideal for laying out tiles directly onto the sublimation transfer to create a mural. The oversized sublimation transfer is position ink-side up on the lower platen and multiple tiles are laid out on top of the transfer facedown on to the design/transfer. The heat platen is then lowered onto the backside of the tile mural for six to eight minutes,and at the end of the cycle, the mural is cooled and packed for shipping or put together as a complete mural.

Ink Jet sublimation transfers are really changing the way we approach decorating all substrates. Get involved and research the possibilities that sublimation decoration offers. Don’t wait – sublimate.