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Although it was widely believed that the dye sublimation printing industry would lose market share to direct printing, the current state of the industry proves that dye sublimation remains the preferred method of print. As a rapidly emerging market segment, many print providers are realizing that recent improvements in dye sublimation inks, printers, and specialty media products are providing them with greater opportunities. These technological advancements have opened the door to a range of new markets and applications by allowing print providers to expand their capabilities beyond traditional dye sublimation applications and into areas that they might previously not have been able to participate.
As this industry continues to grow, the demand for superior transfer papers grows with it. Although there are a wealth of media options available, the biggest gap in the market today from the paper manufacturing side is that of a "hybrid" transfer paper, which carries the unique release attributes that hold relevant to both sides of the sublimation market: rigid and fabric. This article will discuss the need for hybrid transfer papers and detail the wide variety of applications that hybrid papers can produce, from banners and t-shirts to snowboards and tiles—and offer advice to print providers looking to increase profitability.
Dye sublimation is rapidly gaining market share in the US due to the increasing amount of applications that can be produced. One of the major factors fueling this growth is the increasing availability of new and improved combinations of inks, media, hardware, and software that have pushed the quality range of digital media. Prior to these technological advancements, entering the dye sublimation market required a considerable investment in time and money.
With today's wide-format digital printers and the expanding variety of specialty media designed for them, the creative possibilities for creating applications using dye sublimation are endless. By simply investing in new hybrid transfer papers, it is possible to create innovative, high-quality applications that can dramatically increase profitability. Although it may seem like a daunting task, choosing the right media is critical to producing effective dye sublimation applications that meet requirements for image quality.
In the digital imaging arena, the sublimation process takes place in a special laminator in which temperature, dwell time and pressure vary depending on the polymer receiving material. When the heating process is completed, the image on the paper has been fully transferred to the item and has become part of the surface—requiring no surface protection and resulting in a permanent, durable image that cannot be rubbed or washed off.
Surfaces need to be specialty-coated or polymer-coated to accept inks and sublimation conditions vary depending on the heat transfer press being used, making it necessary for print providers to determine optimal temperature, pressure, and dwell time conditions based on individual heat presses. To achieve the best results, dye sublimation should be performed on white or light-colored surfaces.
Dye sublimation papers used for high quality sublimation transfers are designed to print a wide gamut of vibrant colors, while enhancing the release of ink during the sublimation process. By lowering ink use and expense, these specialty media choices help to produce optimal results and ensure product quality. To maintain the performance characteristics of sublimation transfer papers, print providers must handle the media carefully—making sure to store the papers in their protective packaging in 40 to 50 percent relative humidity. Additionally, print providers should allow the papers to attain normal room temperature before using.
Applications to Expand Your Business
As noted, dye sublimation printing can reproduce images on a variety of flexible and rigid substrates, which can endure the amount of heat, pressure and dwell time necessary for image transfer. With two primary areas of focus, including sublimation to textiles/soft fabrics as well rigid substrates, the range of applications is limitless. In today's market, it is fairly common for different specialty papers to be used for each application; however, hybrid transfer papers provide a solution to this market frustration.
In the market today, there are application-specific release attributes that are recognized and important in both the fabric and rigid dye sublimation markets. While some paper suppliers are highly skilled in dye sublimation techniques for fabric substrates; others are more versed in dye sublimation techniques for rigid substrates—causing the need for any sublimation outfit doing both, to outsource from multiple suppliers. This creates a need for two sets of profiles, inventories, price points and product specifications with no overlap. A paper that combines the attributes of both processes allows the streamlining of all of the above mentioned manufacturing components, as well as simplifies the production method. This takes a lot of the guess work out of dye sublimation and ensures the production of not only high quality fabric substrates, but also high quality rigid substrates, using the same media.
To expand productivity and improve profitability, print providers have begun to capitalize on the availability of hybrid transfer papers to produce a world of new applications. The most popular applications include the following:
Fabric Substrates
Clothing and fabrics are the most traditional substrates for dye sublimation. The benefit of sublimating to these material rather than direct printing or heat transfer, is that the inks become part of the fabric through the sublimation process—translating into no fading or distortion over time. Among the most ideal applications that print providers looking to expand their profitability can invest in, include custom clothing such as t-shirts and sweatshirts, point-of-sale applications, and custom flags.
Rigid Substrates
Novelty items are the most commonly used substrates for rigid transfer, presenting a large opportunity for print providers looking to expand their business opportunities. Among the most common novelty items include coffee mugs, key chains, mouse pads, and coasters—all of which can be easily produced by taking advantage of new dye sublimation products and techniques.
Another distinct way to utilize dye sublimation is ceramic tiles. This emerging application provides print providers with a new market segment beyond traditional novelty items—allowing for the creation of unique pieces of art as shown in the image below, or the customization of kitchen counters or bathroom floors.
Lastly, rigid transfer to metal and plastic presents another emerging market opportunity for print providers expanding into the signage market. Typical outdoor signage application and customization of license plates are just few examples of the applications that can be produced using rigid transfer to metal techniques. By taking advantage of similar dye sublimation techniques for transfer to plastic, print providers can also now produce a wide variety of applications, including snowboards and promotional pieces.
Breakthroughs in digital printers, inks, and media are dramatically expanding dye sublimation opportunities for print providers. While creating traditional wide-format applications will continue to provide a steady stream of revenue, investing in new hybrid transfer papers can dramatically streamline the production process—resulting in the expansion of revenue channels.
Jennifer Chagnon serves as product manager, digital imaging for InteliCoat Technologies. She has a strong background in commercialization of manufactured products, as well as experience in marketing and promoting consumer products. For more information, please visit www.magicinkjet.com.
author: BY JENNIFER CHAGNON