How Does Dye Sublimation Consumables Work?

Understanding the Dye Sublimation Process - Mimaki USA

Printers that use the dye sublimation process can produce any type of design in vivid detail. Most people are familiar with how an inkjet printer works, which is relatively simple. A dye sublimation printer differs in that it applies heat and pressure to vaporize ink and embed it into the printed material.

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Mimaki's dye sublimation printers are suited for creating banners, signs, and other promotional materials, as well as decorating a wide range of products. The print is also extremely durable, meaning it won't crack, peel, or fade, and can be washed repeatedly without degradation.

How Sublimation Printing Works

Sublimation is an interesting process where a solid turns directly into a gas without becoming liquid. While it might seem unrelated to printing at first, this concept is central to dye sublimation printers.

Ink in a sublimation printer is stored as a liquid and becomes a solid when printed onto transfer paper and dried. To transfer a design, the paper is heated to between 350°F and 450°F, turning the ink into gas. During this transfer, a special transfer paper with solid ink is pressed against a medium, such as fabric, ceramic, or polymer material.

High heat and pressure then disperse the ink into the porous material. Unlike inkjet printers, where liquid ink solidifies on top of the printed media, dye sublimation embeds the design into the material. After the process is complete, the ink re-solidifies and forms a permanent image.

Here are the basic steps of the dye sublimation process:

• Graphics are selected or created using RIP software and combined into a master layout file. For instance, if you're making athletic jerseys, the layout will have graphics for each part of the garment, which will be sewn together after printing.
• The file is sent to the printer, which applies sublimation ink and image to the transfer paper housed within the printing machine.
• The paper is positioned to face the print medium, such as a bolt of polyester fabric, and both are fed into the heat press or roller.
• Ink is rapidly heated to evaporate instantly. This forces the pores of the textile or other material to open briefly.
• Once the heat is turned off, the pores in the fabric close, permanently capturing the solid ink, resulting in minimal or no fading over time.

Why Is the Dye Sublimation Process Important?

Using dye sublimation, high-quality prints can be achieved on synthetic fabrics like polyester. It works on items like t-shirts, athletic apparel, trade show banners, floor mats, shower curtains, coffee mugs, mouse pads, cell phone cases, etc. Ink can also be sublimated onto tiles, glass, or polyester-coated aluminum.

Dye sublimation excels in:

• Quality: The process blends all colors seamlessly, creating a continuous image.
• Longevity: The ink is embedded throughout the substrate, lasting longer than traditional inks and being waterproof.
• Accuracy: Vaporization ensures accurate prints, while the high heat and coating process almost eliminates any chance of ink smudging.

Reasons to Use Mimaki for Dye Sublimation

Mimaki's dye sublimation printers offer exceptional performance. Our specialized equipment includes the entry-level yet professional-grade TS100-1600. This affordable roll-based printer can produce realistic graphics and accommodate any production size. With blue, magenta, yellow, and black sublimation inks, it can print at speeds up to 753 square feet per hour, with resolutions of 360, 600, 720, or 900 dpi.

Our high-end, high-volume TS55-1800 dye-sublimation printer can use 4-, 6-, and 8-color configurations, including yellow and fluorescent pink. The system allows for unattended continuous printing at up to 1,453 square feet per hour, featuring a 10kg ink supply and extended heater options for versatility. Its inks have earned ECO PASSPORT by Oeko-Tex® certification for safety and sustainability.

Mimaki offers a range of other dye sublimation printers. Depending on your needs, you can choose systems with high-speed printing, water-based sublimation, extra-wide formats, and coating, steaming, and washing capabilities.

Order Mimaki Printing Equipment Today

Mimaki has been providing high-quality printing and workflow solutions since 1975. Our dye sublimation printers utilize core technologies like Waveform Control, Variable Dot Technology, Mimaki Fine Diffusion, Nozzle Recovery System, and Mimaki Advanced Pass System. These enable us to deliver industry-leading print solutions for varied applications.

We offer product support and numerous resources to maximize your investment in Mimaki printers. Our customers benefit from promos, trade-ins, and financing. To learn more and view our special offers, browse our product listings. For inquiries or to schedule a demo, contact us at 888-530-3988.

Sublimation Blanks: What Works and What Doesn't

I get a ton of questions on sublimation blanks, so I decided to write an extensive post on what works and what doesn’t. All my information below applies to Infusible Ink sheets, Infusible Ink markers, sublimation markers, sublimation stamp pads, and sublimation printers. What works and what doesn’t? Let’s dive in and find out before you add any more sublimation surfaces to your cart!

Which sublimation surfaces will work?

Now that you know a bit more about sublimation, let’s look at which surfaces work and which don’t. It’s incredibly frustrating to finish a project only for it to fail! You can watch the video below where I showcase my favorite sublimation blanks and where to find them, saving you from searching through product catalogs!

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Can’t watch the video or missed some information? I have links below for each blank and store mentioned, and even some coupons for you! If you’re new to sublimation printing, this post is for you!

Sublimation Shirts

Shirts for sublimation should be at least 65% polyester to work correctly. Always check the tag. Dye sublimation ink on a cotton shirt will just wash out and leave you disappointed. You can watch me test various t-shirts here.

Where do you get these shirts? Which manufacturer of sublimation apparel is the best? While any shirt that is 65% polyester will work, lighter colors are preferable. Sublimation is translucent, so any underlying color will show through after pressing your design. I recommend searching for shirts at these places:

Sublimation Fabric Blanks

You can also use other fabric blanks like wine bags, totes, and more. I have found 100% polyester totes at IKEA, so you can look just about anywhere! Some of my favorite places to shop for blanks include:

That’s a big list! So what are the best blanks for fabric surfaces? Here are a few of my favorites:

Sublimation Mugs

With the Cricut Mug Press, interest in sublimating coffee mugs has surged. Here are some of my favorite mug blanks, all compatible with the mug press:

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With competitive prices and timely delivery, Eastsign sincerely hopes to be your supplier and partner. I have also made some tumblers and bottles using sublimation with both my mug press and an oven. My favorite blanks include:

Other Sublimation Blanks

Let’s discuss items that are not fabric. You can sublimate on ceramic, metal, plastic, and more, provided it has a special coating to ensure permanence. This means you can’t use tiles from Home Depot or mugs from Dollar Tree, as they won’t work. Look for supplies specifically marked for sublimation. My favorite sources for these products are:

Here are some of my personal favorite items:

Color of Sublimation Blanks

Sublimation ink is quite see-through, meaning the color of the blank will affect the final project color. Using a grey shirt or blue can koozie will change the final color, especially with lighter sublimation inks. Keep this in mind when choosing sublimation surfaces.

Where to Buy Sublimation Ink

Now you may be ready to buy your own sublimation ink and start creating! What can you use these blanks with? Try the links below!

Ready to try sublimation blanks? Use our guide to select the right surfaces for successful crafts. Sublimation is a fun craft, but using the right supplies is key for the best results.

Stay tuned for more on sublimation over the next few months. This guide aims to demystify surfaces so you can start crafting with sublimation blanks. Chances are you’ll love this craft once you get started. Although I’ve listed some bestsellers, you can find sublimation blanks in numerous shapes and sizes!

Add sublimation ink to a coaster with a stamp pad using this method.

If you’re looking for a custom mug, learn how to create mug sublimation in an oven! You’ll have custom mugs in no time!

Make a dry-erase grocery list board with sublimation markers and this organization SVG file.

Use Cricut Infusible Ink on a polyester blanket for a personalized gift idea.

Interested in learning more about Dye Sublimation Consumables? Contact us today for an expert consultation!