Sublimation Process

It's important to begin by emphasizing that none of the processes are a snap and all require some training. I have done screen printing and have a screen print press. However, I send all of my shirt orders to a commercial screen printer. I am not ready to spend $30-$60,000 for a direct-to-garment printer. The print professional in me does not like the color copier heat transfer method -- it just doesn't meet my quality standards. The dye sublimation process offers the most vivid colors and the most versatility of any of the processes. Its biggest downfall, however,
is that you can't print to cotton or dark colored shirts.

 

Here's a brief summary of what's involved with each process.

 

Option 1 - Screen Printing

Screen Printing is the most common process. Pricing can range from a few $$ to $$$ depending on the production demand. The process requires that you create art and then create a film positive. You must have the ability to coat screen and then expose them. Then you need an area to wash out the screen. The next consideration is how many colors do you plan on printing? Most screen printers print spot colors and not CMYK. After the shirts have been pressed, you need a dryer to dry the ink. You would not want to do orders of less than 25 shirts using the screen printing process. There is too much expense involved for short-run jobs.

 

Option 2 - Direct-to-Garment

Direct-to-Garment printing (DTG) is fast becoming a favorite for volumes of 1-25. Companies such as Anajet, Brother and Kornit are just a few of the suppliers of direct-to-garment machines. If you feel a typical volume of 1-25 is your target market, then there are a few things to take into consideration. The direct-to-garment printer by Anajet runs from $30,000 to $35,000. The Kornit is priced upwards of $50,000 to $60,0000. I was interested in printing on dark shirts, such as black. In order to do that you need to make sure that the DTG has white ink capability. You have to lay a white base down on a black shirt before you print any other colors. You also have to pre-treat the dark shirts before they can be printed. Light color or white shirts do not require a pre-treatment. I've also read that if you're looking at this type of machine, it needs to be a closed loop inking system. You will also need a heat press to set the ink after the shirts have been printed. I would recommend talking to several that are using DTG before buying one. Anajet has a book about DTG printing. There is also a trade magazine called Printwear http://www.printwearmag.com that has information in the September issue on "The Digital Direct" including all about DTG printing and the machines on the market.  I would also recommend checking out this website:  

http://www.t-shirtforums.com/direct-garment-dtg-inkjet-printing/

 

Option 3 - Heat Transfers

Heat Transfers from color copiers is the least expensive option if you already have a color copier. You will also need to have a heat press and buy the correct type of paper to run through the copier. The last I used was called Photo-Trans ImageClip made by Neenah paper. Heat Transfers involve a several step process. Once you have printed the transfer sheet image as a mirror image, you lay it together with the receiver paper and press it for the correct time. Then it is peeled apart, laid and pressed on the shirt. The results, in my opinion, are mediocre at best. There are several types of transfer sheets on the market; but I have never had very good luck with any that I have tried. Also the image will begin to fade after a few washes.

 

Option 4 - Dye Sublimation

Dye Sublimation is the process we started doing on campus over 10 years ago. It has limitations: the first is that you can only print on polyester based shirts. Also, you can only print on lighter colored shirts, not black or dark shirts. Sublimation requires a special CMYK dye sub ink and printer, a special type of coated paper that will release the ink when pressed and a heat press. The concept of sublimation is that the printed transfer is heated to 400 degrees and the ink becomes a gas. It is transferred into the polyester fiber of the shirt. The images are permanent and do not peel or fade.  

 

The cost to get into sublimation can be as low as $525 for a Ricoh 3110DN gel printer and inks to an Epson Pro 9700 wide format printer with a Wasatch Rip for around $8300. You will also need a good heat press, not a hobby press that you might find on eBay. A good 16X20 swing away press like we use will run around $1,400. Of course, if you move into the wide format sizes, the heat press can run from $8,000 to $30,000 depending on your needs.  

 

The process of sublimation can lead to other items such as car flags, flip flops, plaques, name badges, mouse pads and even coffee mugs (requires a special mug press). There are hundreds of items that are now available to be sublimated. In my opinion, if you are interested in short-run (1-50) t-shirt orders or short run promo items for your business or campus, the sublimation process is a less expensive diverse market you might want to check out. We use an Epson 1400 printer, Sawgrass Inks, Geo Knight 16X20 Swinger Heat Press and sublimation printing paper.

 

If you have additional questions, Larry Clements can be reached at various times throughout the school day at 405.422.6242 or email him at clementsl@redlandscc.edu