MD.AZMERI LATIF BEGID: 142-32-257

M. Sc in Textile EngineeringSpecialized in Apparel Manufacturing, Processing and Designing

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Sublimation method depends on the use of a volatile dye in the printed design. When the paper is heated the dye is preferentially adsorbed from the vapourphase by the textile material with which the heated paper is held in contact. This is commercially the most important of the transfer-printing methods.

Normally, as matter is heated, it progressesthrough the stages of solid, liquid, then gas.The process of sublimation involves taking matter directly from the solid state to the gaseous state, without becoming a liquid in the process.With a dye sublimation printer, this process allows for ink to be dyed into fabric via heat, which makes the dye permanent and allows for photo-realistic images onfabrics.

Dye sublimation can be used to make a variety of patches for a diverse range of products.Since there is no extra cost associated with adding different colors, you don't have to choose a 1 or 2-color image to save money.It also isn't any more expensive to have full coverage color than spot color.This means you can have work shirts, club hats, and many other items that look great but don't cost more.

Application area

ApplicationDye sublimation is often done on patches because they can then be used on a multitudeof products, including:• Work shirts and jackets• Promotional items• Merchandise for valued customers• Event T-shirts and hats• Uniforms for EMTs, police, firefighters, and municipalities• Hats, shirts, and jackets for cycling groups, motorcycle clubs, sports teams, bands, scout troops, and many othersProduct wise•Shirts• Hats• Key rings• Lapel pinsOr, you can order the patches on their own and have them attached to your own products, such as motorcycle jackets or uniforms.

dye sublimation process by sereen

Screen-printing and other processes for printing images on fabric usually wear off before too long.

By using the dye sublimation process, you save money as well as the environment because the images last just as long as the Tshirts, hats, and other materials the images are printed on.

Benefit of Dye Sublimation

Other processes to transfer images to fabricinclude screen-printing, embroidery, dyes,washes, and appliqués.The problem with these processes is that theimage doesn't last or the process isexpensive, or both.Dye Sublimation allows you to get highquality at an affordable price.

Dye sublimation Printing

Dye sublimation allows photo lab quality picture printing.

During the dye sublimation printing process, an image is

digitally printed in reverse with dye sublimation toners or

inks on to media.

•That image is then placed on top of a fabric and subjected

to high heat and pressure to form a heat press.

•The dye sublimation toners or inks sublimate–the inks go

from a solid state to a gaseous state without becoming

liquid in between and flow into the fabric, dyeing the

threads.

•This creates a gentle gradation of color and does not

distort or fade overtime.

The sublimation name is applied because the dye transitions between the solid and gas states without going through a liquid stage. Many consumer and professional dye-sublimation printers are designed and used for producing photographic prints.

Sublimation printing process is that process which uses heat to transfer dye on to medium materials such as a piece of special paper and use heat to transfer the picture from the paper to the fabric

The dye sublimation inks are a pigment suspended in a liquid solvent, like water. The images are initially printed on coated heat-resistant transfer paper as a reverse image of the final design, which is then transferred onto polyester fabric in a heat press operating at a temperature around 180 to 210 C (375 F). Under high temperature and pressure, the dye turns into a gas and permeates the fabric and then solidifies into its fibers.

Sublimation Sampling Process

Sublimation sampling can be done on Digital printing machine. But digital is not production friendly due to more lead time and cost per meter is high.We can do production using Roller printing machine only for bigger run.

Process-the required design is 1st printed on paper on a roller printing machine for bulk production and then this paper along with the fabric sandwich together and passed thru heated continues paper press to transfer the print from paper to fabric.

Roller printing machine is a machine where copper rolls are used for printing and any design with multiple color merging, ombray effect can be achieved for bulk production, since the copper roll are very- very expensive so this printing machine is no longer used in Indian textile industry but frequently used in china and Korea to achieve excellent print result in heat transfer/sublimation print

Any print that digital printing machine produced and rotary can’t do, can be achieved using roller printing machine thru sublimation process.The combination of heat and pressure cause the sublimation ink to convert into a gas, which is received simultaneously by the substrate’s opened polymers. (This is an over-simplified explanation of the process, but it works for our purposes.) After the heat application is completed (about a minute), the transfer paper is removed and discarded. When the product cools down, the sublimation dye is encapsulated within the surface (instead of on top). The result is a high-resolution, permanent coloration that won’t peel or crack. And in the case of apparel, sublimation will not fade, even after multiple washings.

Advantage of sublimation

Any image can be printed all over the fabric The result of heat transfer printing and digital printing using low sublimation disperse dyes would be the same.Colors can be extraordinarily brilliant due to the bonding of the dye to the transparent fibers of the synthetic fabric. Truly continuous tones can be achieved that are equivalent to photographs, without the use special techniques such as half-screen printing.

Disadvantage of sublimation•Back side of fabric always be white as it only prints the surface of the textile.•Sampling cost is high.•Cost and lead time will be high for smaller run.•Not success for light weight qualities like chiffon, ggt.•If we stretch the fabric 20% or more then you lose a whole stack of color depth when the white shows through the fabric/knit ribs (dark blue suddenly becomes light blue, black becomes grey).•Sublimation heat transfer is suitable for polyester fabric only.The limitation of sublimation is that it only works on polymer-based surfaces,

Difference between Sublimation and Digital Printing

Sublimation Printing

• Paper image is transfer on the surface of the polyester fabric.

• There is no need of fabric to be coated.

• Base fabric should be synthetic or 100% polyester,

• Disperse dyes are used

• Sublimation will not fade, even after multiple washings

• Sublimation dyes does not penetrate the surface of fabric. So back side of fabric always white.

• Production feasible and less costly for bigger run.

Digital Printing

• The inks are printed directly to the coated fabric.

• There is need of fabric to be coated .

• All fabric can used as base except polyester or synthetic.

• Reactive dyes are used

• Digital print can get fade after multiple washing.

• In this dyes penetrate the surface of base fabric. Digital relying on molecular bonding,.

• It is not production feasible , Ideal for sampling only.

Sublimation and Digital Printing

Conclusion

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