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The basic inkjet dye sublimation process uses a heat
sensitive sublimation dye, dissolved in a liquid, to print graphics and text
onto special inkjet paper. This is called a dye sub transfer. The dye sub
transfer and a sublimatable item are then placed into a heat press.
When the heating cycle is completed, the image on the paper
has been transferred to the item and has actually become a part of the surface.
Run your finger across the surface of sublimation and you will feel nothing.
The reason for this is that sublimation is always done on a
polyester, polymer, or polymer coated item. At high temperatures, the solid dyes
in the print converts into a gas without ever becoming a liquid. The high
temperature also opens the pores of the polymer and allows the gas to enter.
When the item is removed from the heat press, the temperature drops, the pores
close and the gas reverts to a solid state. It has now become a part of the
polymer. Done correctly, it cannot be washed out or come off, unless the actual
fibers or coating is damaged.
This is why Inkjet sublimation can't be done on natural
materials, like 100% cotton. Natural fibers and non-coated materials have no
"pores" to open and so the dye just sits on top of the fabric. Heat transfers
are the best way to imprint cotton and cotton-blend fabrics.
99.9% of inkjet sublimation is done on white materials
(substrates is the technical term). The reason for this is because the inks are
actually transparent, when sublimated, and need a background to show up. White
is the ideal background because it does not clash with the colors. Indeed, the
white background actually enhances the colors.
This allows sublimators to print a wide gamut of vibrant,
brilliant colors on multiple substrates. Some of the items include Soft-Link™
T-shirts (a cotton shirt, with a micro-weave of polyester on the outside),
colored mesh ball caps, with a polyester front, mouse pads, jackets, beverage
insulators, polyester calendars, clock faces, doll clothes, polyester patches,
ceramic plates, mugs and tiles, FR plastic, coated MDF hard board (coasters,
clipboards, etc.) and many other items.
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