As T-shirt printing technology advances, more options are available than ever before, including dye sublimation printing, screen printing, heat transfer and direct-to-garment (DTG) printing. To make the best choice for your T-shirt project, you need to understand how these printing methods work and the pros and cons of each.
In this article, we’ll break down dye sublimation printing on fabric, compare sublimation vs screen printing and touch on other popular T-shirt printing methods like heat transfer and DTG. So whether you’re a small business owner printing team uniforms with your branding or an entrepreneur launching a merchandise business, we’ll help you decide whether dye sublimation printing is the right method for your needs!
- Dye sublimation printing is a printing method that uses heat and pressure to bond sublimation ink directly into polyester fibers.
- While dye sublimation printing creates photorealistic, seamless prints with exceptional durability and the ability to handle intricate, full-color designs, a lack of white ink means you can’t print on dark-colored fabrics and it’s limited to polyester fabrics.
- Screen printing is a versatile and cost-effective printing method where ink is pushed through a stencil-like mesh screen onto fabric, creating bold, vibrant prints. However, it requires a lengthy setup, struggles with intricate designs and prints can crack or fade over time.
- Dye sublimation printing is ideal for small runs of vibrant, personalized designs on polyester T-shirts, while screen printing excels at bulk orders with bold, simple graphics.
What is dye sublimation printing?
Dye sublimation printing is a printing method that uses heat and pressure to transfer designs directly onto fabric. Although this might sound similar to heat transfer printing, the two methods are actually quite different. While both involve heat, the main difference is how the design interacts with the fabric.
Sublimation is when a substance transitions from the solid to the gas state, without passing through the liquid state. So, with sublimation printing, solid dye is heated until it turns directly into gas, which then seeps into the fabric and bonds with polyester fibers, embedding the design into the material. This is why dye sublimation printing creates smooth prints that become part of the fabric itself, unlike heat transfer prints, which sit on the material’s surface.
Dye sublimation printing on fabric: Step-by-step guide
The whole “solid to gas” process of dye sublimation might sound like magic, but it’s really just physics in action—and some help from the right equipment.
As we’ve already covered, sublimation embeds designs directly into polyester fabric by turning ink into gas and bonding it at a molecular level. But how do you actually make that happen? Let’s break down the step-by-step process and the tools you’ll need to transform your designs into vibrant prints.
Equipment needed for dye sublimation printing
- Dye sublimation printer
- Sublimation ink
- Sublimation transfer paper
- Heat press machine
- Polyester fabric
- Cutting tools
- Heat-resistant gloves
- Heat-resistant tape (optional)
- Protective sheets (optional)
Step 1: Print the design onto sublimation transfer paper
Since this article is all about T-shirt printing, we’re going to assume you’ve already got your T-shirt design ready to go. If not, that’s where you’ll want to start—every great T-shirt begins with a great T-shirt design.
Once your design is set, load a dye sublimation printer with sublimation ink cartridges. Sublimation ink is unique because it transforms into gas when exposed to heat. Regular printers and standard inks won’t cut it. Then print your design onto sublimation transfer paper. Remember to mirror your design before printing it.
Step 2: Prepare the fabric
The T-shirt fabric you choose is crucial. When it comes to dye sublimation printing on fabric, only 100% polyester or polyester-coated materials will work (one of the downsides of the method).
After checking your T-shirt is clean, dry and free of lint (even a tiny speck of dust can mess with your print), give it a quick pre-press in a heat press machine to smooth out wrinkles and remove any moisture.
Step 3: Position the transfer paper onto the fabric
Place the printed transfer paper face-down on the fabric, aligning the design exactly where you want it. This small step can make a big difference in ensuring sharp, accurate results.
Secure the paper with heat-resistant tape to keep everything in place and avoid any shifting during the pressing process.
Step 4: Heat press the design
Place the fabric and transfer paper into a heat press, set the temperature to 350°F to 400°F (177°C to 204°C) and let the heat do its work. In just 45 to 60 seconds of medium to firm pressure, the sublimation ink transforms into gas and bonds with the polyester fibers at a molecular level. Carefully lift the heat press and peel off the transfer paper while still warm. The design is now part of the fabric!
Step 5: Cool and inspect the final product
Let the fabric cool naturally or place it on a cooling surface. Then, take a moment to inspect your work. Check for alignment, consistency and color vibrancy. This is your chance to make sure the final product lives up to your expectations.
Pros and cons of dye sublimation printing
Like any printing method, dye sublimation has its pros and cons. Understanding these can help you decide if it’s the right fit for your T-shirt printing business or a one-off project.
Pros of sublimation printing
- Exceptional print quality: Creates detailed, high-resolution designs with vibrant colors using CMYK inks
- Durability: Produces long-lasting prints that resist peeling, cracking or fading over time
- Smooth finish: Embeds the design directly into the fabric, resulting in a seamless, professional look
- Intricate designs: Reproduces even the most complex designs with precision and consistency
Cons of sublimation printing
Despite its considerable pros, there are some drawbacks of dye sublimation printing…
- Fabric limitations: Only works on polyester or polyester-coated materials, making it unsuitable for cotton fabrics
- Higher costs for bulk orders: More expensive compared to other methods when producing large quantities
- Specialized equipment required: Requires dye-sublimation-compatible printers and heat presses, which can be a significant investment
- No white ink: Doesn’t print the color white, so designs rely on the base color of the fabric for white or lighter areas
Why can’t you produce white color using dye sublimation printing?
CMYK inks are the magic behind dye sublimation’s exceptional print quality and vibrant colors—but they’re also its Achilles’ heel. Since white isn’t part of the CMYK lineup, sublimation printers can’t produce it. Instead, any “white” areas in your design are left blank, showing the fabric’s base color instead. And if your blank T-shirt is dark? Those white details won’t show up at all, making dye sublimation less than ideal for dark fabrics or designs that need crisp, bright whites.
Sublimation vs screen printing: Which is best for your project?
When choosing between screen printing and dye sublimation printing on fabric, it’s important to match the method to your project’s needs. Each has unique strengths and limitations, depending on the material, design and scale of your production. This detailed comparison across ten factors can help you decide which one fits your T-shirt printing goals.
Result of screen printing
Result of sublimation printing
Material limitations: What fabrics can you print on?
The type of fabric you choose makes a big difference in which printing method will work best.
- Dye sublimation printing bonds ink directly to polyester fibers, so it’s limited to 100% polyester or polyester-coated materials. Unfortunately, natural fabrics like cotton don’t make the cut for this method.
- Screen printing is more versatile: its inks sit on top of the fabric, making it compatible with cotton, blends and darker fabrics, as well as polyester.
Design complexity: How intricate is your design?
- If your design is bursting with gradients, fine details or photorealistic elements, dye sublimation printing is a clear winner. It uses CMYK ink and a digital process, which means no color combination limitations and razor-sharp precision for even the tiniest details.
- Screen printing thrives on simplicity. It’s perfect for bold logos, clean text or graphics with a few solid colors. But throw in complex multi-colored designs with gradients and things get tricky (and expensive), as each new color requires its own screen.
Fabric color: What blank T-shirts are you working with?
- Dye sublimation printing loves light fabrics. Since it doesn’t use white ink, any white areas in your design will take on the fabric’s base color. This makes it best suited for white or light-colored T-shirts.
- Screen printing doesn’t shy away from dark fabrics. Opaque inks can be layered on top of darker materials and you can print light-colored designs using white ink, creating vibrant, eye-catching designs.
Quantity of T-shirts: How many do you need?
- If you’re working on a small order or even a single T-shirt, dye sublimation is your best bet. It skips the complicated setup and gets straight to printing, making it cost-effective for one-offs or small batches.
- While the setup is more time-consuming and costly, the cost per shirt drops significantly as your order size increases, making screen printing ideal for large orders or bulk production.
Cost: Is budget a factor?
- Dye sublimation printing is budget-friendly for smaller projects since it doesn’t involve extra setup costs. However, because the cost per shirt remains constant, larger orders are less affordable.
- Screen printing requires an upfront investment to prepare the screens, but once that’s done, the cost per shirt decreases with higher quantities, making it a more economical choice for bulk orders.
Production time: How quickly do you need it?
- Dye sublimation printing is faster for small runs because it doesn’t require screen preparation. Once your design is ready, the straightforward digital process can begin almost immediately.
- Screen printing requires more time upfront to create individual screens for each color in the design. However, once the screens are prepared, bulk production is much faster compared to sublimation.
Durability: How long will the print last?
- Dye sublimation printing offers unbeatable durability. Since the ink becomes part of the fabric, it won’t peel, crack or fade, even after countless washes.
- Screen printing is durable too, but because the ink sits on top of the fabric, it’s more prone to cracking or fading over time, especially with frequent washing. With proper care, though, screen-printed designs can still last a long time.
Texture of print: How does the print feel?
- Dye sublimation printing creates a smooth, seamless finish. Because the design is embedded into the fabric, there’s no texture—just the feel of the fabric itself.
- Screen printing, by contrast, leaves a slightly raised texture where the ink is applied. This texture can be more noticeable depending on the thickness of the ink.
Customization: Are your designs personalized?
- If you’re in the print-on-demand business and looking for a printing method that allows for personalized designs — like T-shirts with individual names, numbers or photos — dye sublimation printing is the way to go. Each print can be unique without requiring extra setup.
- Screen printing is better for uniformity. It’s great for producing the same design across a large batch, but changing designs requires creating new screens, which can add time and cost.
Eco-friendliness: Which is more sustainable?
- Dye sublimation printing is a low-waste process since it’s entirely digital, but polyester fabrics aren’t always the greenest option.
- Screen printing can create more waste due to inks and screen preparation, but using water-based inks and eco-friendly practices can make it a more sustainable choice.
How does dye sublimation printing compare to other methods?
Now you understand how dye sublimation printing on fabric stacks up against screen printing, what about heat transfer and direct-to-garment printing? To simplify things, we’ve prepared a cheat sheet comparing all four popular T-shirt printing methods across key criteria.
Result of DTG printing
Result of heat transfer printing
| Factor | Sublimation printing | Screen printing | Heat transfer | DTG |
| Ink application | Ink bonds with polyester fibers at a molecular level | Ink sits on top of the fabric | Adhesive layer transfers ink onto fabric | Ink sprays directly onto the fabric |
| Best use cases | Personalized T-shirts, sportswear, intricate promotional designs | Bulk orders, employee uniforms, bold logos and simple graphics | One-off designs, small custom orders, affordable promotional materials | Photorealistic designs, short runs and small custom orders |
| Fabric type | 100% polyester or polyester-coated materials only | Works on cotton, blends, polyester and dark fabrics | Works on a variety of fabrics, including cotton and polyester | Best on 100% cotton but works on blends |
| Print quality and design detail | Vibrant, photorealistic and handles intricate, full-color designs seamlessly | Excellent for bold, simple designs but struggles with intricate patterns | Good quality but less vibrant; handles basic designs well | High-quality prints with sharp detail and vibrant colors |
| Print durability | Extremely durable; won’t peel, crack or fade | Durable but can crack or fade with frequent washing | Moderate durability; prone to peeling and fading | Durable, though may fade slightly over time |
| Feel of print | Smooth, embedded into the fabric | Slightly raised texture from ink sitting on top of the fabric | Noticeable layer on top of the fabric | Smooth, soft feel |
| Cost for small batches | Cost-effective for one-offs or small runs | Expensive due to setup costs | Affordable | Affordable |
| Cost for large batches | Expensive due to per-print pricing | Very cost-effective | Less cost-effective for large orders | More expensive for bulk production |
| Print setup time | Minimal setup, no additional preparation needed | Long setup; separate screens must be prepared for each color | Minimal setup | Minimal setup |
| Production time | Quick for small runs, slower for bulk orders | Fast production for large order | Moderate production time | Moderate production time |
| Eco-friendliness | Low waste during printing but relies on polyester fabrics | Produces waste (inks, screens) but water-based inks are a greener option | Moderate waste from transfer sheets and adhesive layers | Moderate; uses water-based inks but generates waste in maintenance |
Ready to bring your print project to life?
Choosing the right T-shirt printing method for your business or project is all about knowing what works for your needs. Dye sublimation is your go-to for small batches of vibrant, personalized designs on polyester fabrics. It’s seamless, durable and perfect for intricate, colorful designs.
But you don’t have to navigate the world of T-shirt printing alone. VistaPrint is here to make the process easy. With expertise in dye sublimation printing and other printing options, from screen printing to DTG, we have the tools to bring any T-shirt project to life.
FAQ about dye sublimation printing
How long do dye sublimation prints last?
Dye sublimation prints are incredibly durable and can last for years without peeling, cracking or fading. Since the ink bonds directly with the fabric, the design becomes part of the material itself, withstanding frequent washing.
Is dye sublimation good quality?
Yes! Dye sublimation printing produces sharp, vibrant, high-quality results with photorealistic detail, ideal for intricate designs and full-color artwork.
What is the best fabric for dye sublimation printing?
The best fabric for dye sublimation printing on fabric is 100% polyester. The printing method can also work well with polyester-coated materials.
Is dye sublimation printing good for T-shirts?
Absolutely! Dye sublimation printing is perfect for creating vibrant, detailed T-shirt designs, especially on white or light-colored polyester fabrics.
Is dye sublimation printing the same as heat transfer?
No, dye sublimation printing and heat transfer are different. While both use heat, sublimation transforms solid ink into a gas, bonding it with polyester fibers, whereas heat transfer applies a design onto the fabric surface using a transfer paper and adhesive layer.
