In the past year, textiles seem to have suddenly become a particularly good substrate for printing. This kind of favored printing materials naturally caused controversy, especially regarding the comparison between dye sublimation transfer printing and dye sublimation direct printing technology. Dye sublimation is completely different from any other wide-format inkjet printing technology. It produces very vivid colors and rich reproduction of details. Below we will compare the differences between the above two dye sublimation printing technologies and consider the benefits and deficiencies associated with them.
The basis of two types of dye sublimation printing technology
Dye sublimation transfer technology requires the use of a digital printer to generate a reverse image on a coated transfer paper. Then, the image is transferred from the paper to the final substrate by heating. The substrate can be either a polyester fabric or other polyester or polyester coating materials. Sublimation inks can be water-based inks, solvent-based inks or oil-based inks, usually provided in the form of four primary colors + complementary colors to increase the color gamut.
Sublimation refers to the direct transformation of a substance from a solid state to a gaseous state without the need to go through a liquid state in the middle. The atomization or vaporization of dry ice at room temperature is a common example of sublimation.
Use a hot press with an operating temperature of approximately 356 to 410 ° F (180 to 210 ° C) to transfer sublimation ink from the transfer paper to the final substrate. Under the action of high temperature and pressure, the dye turns into gas and penetrates into the fabric, and then solidifies in the fabric fiber. When the dye sublimation ink is heated at a temperature of approximately 390 ° F (200 ° C), it will immediately become a gas. The heat will also open the pores of the polyester or polyester coating medium, and then the gas penetrates into the material. When the heat source is removed, the sublimation ink will become solid again, and the pores of the polyester material are closed, thereby sealing the ink in the polyester material. If the operation is correct, since the image has almost become part of the substrate, there will never be discoloration, cracking, or damage.
Dye sublimation transfer technology first performs digital printing on transfer paper, and then transfers the image to the fabric; while direct dye sublimation printing technology directly prints on the final substrate without using transfer paper. The fabric suitable for direct printing of dye sublimation has a special coating, which is its special feature; the printed dye sublimation ink mainly floats on the surface of this layer. When the fabric is heated on the online heating unit, the sublimation ink that penetrates into the fabric will form a permanent image.
Direct printing of dye-sublimated fabrics may be a more cost-effective technology, with better ink penetration on fabrics. However, the use of transfer paper can produce better image quality, especially in detail reproduction and edge definition. Since the fabric does not have the fluid absorption properties of paper, the transferred image provides the same fidelity as a real photo. However, for flags and other applications that require the use of impregnated fabrics in order to obtain eye-catching colors on both sides, direct printing technology shows its value.
One of the main advantages of the above two dye sublimation printing technologies over UV and solvent inkjet printing technologies is that dye sublimation printing can produce a wider color gamut. The vividness and strength of sublimation inks give POP designers a wider choice.
Whether you decide to choose dye sublimation transfer technology or adopt dye sublimation direct printing technology, you must keep in mind equipment cost, image saturation and quality, consumable cost (ink and fabric), and labor / universal considerations. Some printing equipment requires the use of hot presses, while other printing equipment features a random carrying heating device, thereby eliminating the need for human intervention. A printing press and thermal transfer device are the minimum requirements for dye sublimation transfer, and the cost will increase exponentially with the increase in width. The same price concept also applies to dye sublimation direct printing, at which time you can purchase an online system or an integrated system again.
Consumables
The application of dye sublimation technology has existed for many years. Through the hard work of industry suppliers, the materials related to this technology have been improved. Water-based and solvent-based dye sublimation inks are most commonly used in dye sublimation transfer. Water-based inks usually produce richer details and high-quality images with better colors.
However, due to the large amount of water contained in the water-based sublimation ink, it is inevitable that it will penetrate the transfer paper, causing wrinkles in the paper, so this type of ink is struggling in the field of wide format output. Water will decompose the organic materials in the paper, causing the paper to ripple. That is to say, printing presses are increasingly using water-based inks to produce better printing results on newer and larger papers, and new papers can achieve greater ink deposition.
Ink manufacturers have introduced solvent-based dye sublimation inks to help these inks enter the ultra-large format field. This is one of the advantages of solvent-based inks. Another advantage is its good printing stability and high color density. Many ultra-wide solvent-based dye-sublimation printers can be converted from solvent-based dye-sublimation inks to conventional solvent-based inks suitable for vinyl materials without much effort. In addition, the solvent-based dye sublimation ink has a very wide color gamut, and the black is very dense, so that it can make POP materials needed in many fields. However, because the printing price per square foot of solvent-based dye sublimation ink and conventional solvent-based ink is very close, the price is not a big factor.
Fabrics are also an important consumable. Conventional fabrics have seen leapfrog development in the field of dye sublimation printing. Dye sublimation direct printing technology requires the use of coated fabrics, first printing the ink on the fabric, and then heating it to transfer it into the fabric. The layer always gives the fabric hardness, but it does not have this hardness for the non-coated fabric used in the dye sublimation transfer process. Dye sublimation requires fabrics with high polyester content. Many existing non-coated polyester fabrics can add points to dye sublimation transfer technology.
Fabric structure and other options are also often beneficial to dye sublimation transfer technology, and cost factors make non-coated fabrics a real winner. Depending on availability and competition, the cost of dye-sublimation direct printing media will be double to five times that of similar non-coated fabrics. Cost analysis seems to be self-evident: when we strictly evaluate the cost of fabrics, although the cost of transfer paper increases the cost per square foot of fabric by 20%, long-run printing jobs are most suitable for dye sublimation transfer technology.
Ease of use
Dye sublimation direct printing technology requires the use of an employee to operate a roll-to-roll printing system. The manufacturers of these systems endeavor to recommend the ease of use of dye sublimation direct printing technology. However, the disadvantage is that printing a job means that another job must wait. In the dye sublimation transfer process, the printed fabric will be sent to the transfer equipment, so that the printing machine can be prepared for the next rocket. Since the sublimation process takes place off-machine, the printing press can start producing the next job more quickly.
I also view workflow management as a key issue, and I should focus on this issue to decide which technology to use. Dye sublimation direct printing technology has the characteristics of single-person operation and integrated online workflow. If the printing enterprise does not have enough space and manpower to accommodate multiple devices related to dye sublimation transfer, this technology may be a better s Choice.
Workshop climate is another major consideration for dye sublimation transfer technology. Transfer paper is very sensitive to moisture, and in an uncontrolled environment, a large number of failures will follow. Changes in temperature and humidity can cause severe damage to high-release transfer paper, leading to paper curl, size changes, and other problems. Daily and seasonal assessments of humidity, especially during the summer and winter months, must be part of the quality control process. The greater the humidity in the workshop, the higher the degree of moisture transfer of the transfer medium. Moisture can cause uneven image transfer and ink chromatic aberration.
Fabric dye sublimation direct printing technology is less sensitive to environmental factors that can disrupt the transfer workflow. However, if there is a problem with the transfer paper, the damage caused is still negligible; but if there is a problem with the fabric, it will pay a high price.
Dye sublimation direct printing as today's technology is most suitable for printing companies that want simple processes or POP printers who want to enter the field of fabric decoration. Despite the flexibility of dye-sublimation direct printing technology, fabric restrictions do pose a problem for creative customers. Dye sublimation transfer technology allows companies to apply a set of workflows to multiple devices. Although it requires a certain degree of environmental control, it has greater flexibility for the media.
opportunity
Dye sublimation printing opens the door to opportunities in countless applications. In addition to the POP display, you can attract income through interior decoration, Wall Hangings, high-end decoration, living room dividers, art reproductions, educational or informative displays in schools and museums, various soft signs, banners and other products Trickle down. No matter what dye sublimation printing technology you end up with, you will get a way to help you explore new areas and markets. Who knows? Perhaps dye sublimation technology will even become the cornerstone of your career.
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