The Dye Sub Column
Dye sublimation vs. screen printing
In this article, industry veteran Jason Chapman of BezierOne outlines the differences between two very different printing processes – dye sublimation and screen printing.
S
creen printing and dye sublimation are two distinct printing methods used to transfer designs onto various materials,
especially textiles.
Here’s a breakdown of each process… Screen printing
Screen printing is a traditional method of printing that involves the following steps: 1) Stencil creation: A stencil or design is created on a fine mesh screen. The areas that you want to print are left open, while the rest of the screen is blocked.
2) Ink application: Ink is pushed through the open areas of the screen using a squeegee, transferring the design onto the material (e.g. fabric, paper, or plastic).
3) Layering: For multi-coloured designs, multiple screens are used, one for each colour, and each colour is printed separately.
Screen printing is known for:
• Producing vibrant, long-lasting colours. • Being cost-effective for large runs. • Working well on a variety of materials, including fabrics and plastics.
Dye sublimation
Dye sublimation is a more modern printing process that works best on polyester-based fabrics and some coated materials: 1) Design creation: The design is printed onto a special transfer paper using sublimation ink.
2) Heat transfer: The transfer paper is placed on the material, and heat and pressure are applied. The heat causes the sublimation ink to turn into a gas, which then bonds with the fibres of the fabric.
3) Permanent bond: The dye becomes part of the fabric itself, resulting in a print that won’t crack, peel, or fade over time.
Dye sublimation is known for:
• Producing detailed, high-quality images with smooth gradients.
• Being ideal for printing on light-coloured, polyester-based fabrics.
• Creating durable prints that are soft to the touch, since the ink becomes part of the fabric.
Screen printed dye sublimation
While screen printed dye sublimation is not a common term (since the two methods are quite different), it might refer
| 66 | October 2024
to a combination of screen printing and dye sublimation in specific cases. • Screen printing for large runs: Screen printing may be used for simpler designs or large batches, while dye sublimation could be used for detailed, photographic-quality prints on smaller items or specific sections.
• Hybrid approach: A business may combine the two processes based on project needs, such as screen printing logos on shirts but using dye sublimation for more intricate designs or backgrounds. Each method has its strengths, so choosing the right one depends on the type of material, the complexity of the design, and the desired durability of the print.
Wind back the clock to the 1980s… “By the 1980s the RGS Group had over 175 employees and a turnover of over £7 million. All work processed by us, not just imported and sold on. It was at this time that we helped another Ossett manufacturer, Burmatex to show them how to make carpet tiles. They have made them ever since. However, they soon obtained their own carpet tiling machinery, leaving us a little ‘high and dry’. We had again to innovate for the tiling programme. We knew that plain carpet tiles would sell better if some of them were patterned. Luckily, our knowledge of printing benefited us. In 1976, we invented and patented the process of sublimatic printing onto 3D substrates, i.e. pile carpet. Firstly, we silk-screen printed patterns with deep penetrating, sublimable inks onto paper and by heat in a partial vacuum chamber, and pressure from a heated platen, the design was transferred onto the substrate (the tile, or rug). The vacuum transfer machinery was patented by us, and made by Spooner Industries of Ilkey.”
– Richard Glover (RGS)
I started my printing career at RGS in the late 80s printing the actual sublimation transfers Richard discusses. There were strict controls we had to follow back then such as controlling the density of each and ensuring all four corners of the printed sheet was balanced and in tolerance.
Secondly the paper itself back then was very absorbent and humidity in the factory was a major influence on performance. These days, we have transitioned into inkjet and other digital printing methods. While the operational environment and materials are much easier to handle, moisture (humidity) is something that sublimation printers around the world should monitor as good practice. Simple humidity monitors around the printing, pressing and storage areas, especially before pressing.
www.printwearandpromotion.co.uk
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