With the rapid development of digital printing technology in recent years, previously used analog printing methods have begun to become a thing of the past. While methods such as screen printing, dyeing, special washing and aging, laser processing, embroidery or applique were previously used to give patterns and colors to textile fabrics, with sublimation printing, many more applications can be made with much easier methods, in fewer quantities and in shorter periods of time. . Thus, it was possible to easily print the desired image in applications such as all ready-made clothing, upholstery fabric, promotional products, sportswear products, flags and fabric-based advertising products. Moreover, with a very wide color gamut and photographic print quality.
However, there are many points to consider for those who want to create new job opportunities and achieve more profitable production by starting sublimation printing production. We have compiled all the curiosities, from the printing machine to the RIP program, in order to make maximum use of the opportunities that sublimation printing offers to the manufacturer and to achieve the highest quality in the final product.
What is sublimation printing?
We can briefly call sublimation printing a method of transferring and printing any design onto the fabric. The most important feature that distinguishes sublimation printing from other analog methods is that hand-held printing has almost photographic quality and this quality can be achieved quite easily. All you need is the fabric you will print on, transfer paper and paint.
The operation of printing involves a process known as “sublimation”. The sublimation process is the direct transformation of a chemically solid substance into gaseous form without liquefaction. Therefore, in sublimation printing, the process continues by transferring the microscopic solid particles in the ink to the special coated transfer paper with a special transfer printing machine. Then, when this paper is placed on the fabric and pressed with heat, the solid particles in the ink turn directly into gas and are transferred to the fabric. For this purpose, applying heat and pressure, a rotary calendar or special protective paper is used. In order to carry out this process, the dye only needs to be processed on polymer, that is, synthetic. Therefore, sublimation printing cannot be done on surfaces with natural fibers, such as 100% cotton fabrics.
Transfer printing machines
The printing press is just one step in the sublimation printing process. After printing, heat pressing equipment is required to transfer the image to the fabric.
As it is known, there are transfer printing machines on the market that offer many different features and advantages. However, the most important thing is to invest in machinery according to the requirements of the printing application. For example, while small format printing machines will be sufficient for small quantities and piece prints, large format printing machines are more ideal for upholstery fabric, large format advertising and display application products or for high volume production.
In order to decide on the right machine, special technologies offered by machine manufacturers are of great importance. The software used by the machine controls the paint consumption and keeps it at an optimum level; the software offers the best color management methods to achieve accurate colors; the machine has additional control mechanisms to prevent the printing roller from slipping; Among these features, the machine has automatic features that will require a minimum of the printing operator and automatic control systems that will minimize negative situations affecting quality due to user error.
heat presses
Choosing the right heat press is as important as the printing machine. It will always be an advantage if the heat press is slightly wider than the maximum printing size of the press. When you choose a larger size printing machine in the future as demand increases and orders increase, using the existing heat press will be more profitable in the long run.
Besides the size of the heat press, the most important issue is of course quality. The quality of sublimation printing is directly related to processing time, temperature and pressure settings. It is crucial that the press delivers consistent, high-quality results on the fabric. It is recommended that orders be placed immediately after installation of the machine, after testing what the optimal pressure and temperature values are for your material. Thus, you can save both time and cost in the subsequent process, minimize the use of wasted materials and achieve greater efficiency.
transfer printing paper
As mentioned above, the quality of the transfer paper on which the print will be made is one of the most important factors that will affect the visual quality of the product. By using specially coated papers, it is possible to make high quality prints on all fabrics.
The most important point here is the features offered by the coating of the transfer paper. Since ink costs are generally quite high in the market, printing manufacturers are experiencing serious difficulties. When printing on any uncoated paper available on the market, more than 50 percent of the ink remains on the paper. When specially formulated coated papers are preferred, 90 percent of the ink can be transferred to the fabric, resulting in very high quality printouts for printing the final product.
Additionally, one of the most important points to pay attention to when using transfer paper is the ink absorption of the paper. Under normal circumstances, when the ink is printed on the paper, the ink should dry and the paper should absorb that ink. When the paper absorbs this, it is not transferred to the fabric and there is a loss of ink. In coated papers, the ink dries very quickly, preventing loss of ink and providing a significant advantage in productivity.
inks
Sublimation dyes are different from standard inkjet dyes; Many come in cartridges or large liter paint bottles. In order to get the best efficiency from your machine, you must use the inks offered by your machine supplier or high-quality inks suitable for the print head of your machine. In addition, for the most efficient and trouble-free use of sublimation dye, the machine, RIP programs and color profiles must be used correctly.
The first requirement is that the inks you will use in sublimation printing are compatible with the print head of the machine. It is then important to achieve smooth paint flow without causing head clogging. Therefore, particle sizes must be appropriate. In this way, the paint sprayed from the head does not cause problems such as ghosting or overflow. On the other hand, it is also extremely important that the paint has a fast drying time, offers a wide color gamut, does not contain harmful components and has environmentally friendly features.
Dye sublimation inks used in sublimation printing provide more vibrant colors than pigment inks and can be applied to the desired surface. It is completely safe to use, environmentally friendly and harmless to human health.
RIP Programs and Color Management
One of the greatest conveniences offered by sublimation printing compared to traditional methods is its very wide color gamut and the possibility of printing the desired pattern on the fabric. However, while print manufacturers who are just starting to start sublimation printing thoroughly research machinery, paint and paper products in the first stage, choosing the right software is often neglected. However, as with all digital printing technologies, obtaining the correct color and ensuring color consistency in printing is possible with correct color management.
In digital printing, the color seen on the monitor and the colors obtained as a result of printing may vary depending on the machine and monitor. At this point, correct color management is vital in most cases. Therefore, in order to carry out correct color management in sublimation printing, the right machine and compatible ink must be selected, but in order to choose the right RIP software, the features and functions offered by the software package must be investigated.
Environmental impacts
One of the biggest advantages of sublimation printing is that it offers a safe option for both the environment, the printing environment and the operator. Sublimation printing is the most harmless, environmentally friendly and sustainable method among textile printing processes and does not produce waste. Because the printing process takes place by the direct transformation of solid particles into gas form, there is no need to use unnecessary water. Compared to traditional methods such as screen printing, which use very high amounts of water, it reduces the waste water rate to zero and offers a lower-cost printing process.
Working conditions
The only point to be considered during the sublimation printing process is that the employee does not come into contact with the heat press. Apart from this, there is no such thing as gas emissions harmful to human health released into the environment during the printing and press stage.
