Choosing the right printing method for your project.

Choosing the right printing method for your project.
How to choose the right printing method

Choosing the right printing method for your project.

By Pete Apo

There are many different types of printing methods so choosing the right printing method for your project is essential to getting a great final result. Understanding the differences, mainly in how they are priced and their individual limitations and benefits, will enable you to choose the right printing method. You will need to possess a few key details regarding your printing job: Quantity, Product or Material, Number of Colors in Design, and Basic Size or Print Location. In this article I will list the most common printing options and state the limitations and benefits of each one.

Screen Printing

Pricing- Screen printing price is based mainly on the quantity of prints and number of colors in each print. Each color added to the print location will incur an additional set-up and per-piece charge. The higher number of pieces or prints will cause the per-print price to be lower, determined by quantity price breaks like 12 (minimum), 24, 48, 60, 72, etc.

Color Limitations– We are typically able to print up to six colors for your design on screen printed items, however, certain materials and/or locations might put additional limitations to this number. Complex gradients using multiple colors might be difficult to achieve using a screen printing method, so it is recommended that you send us your artwork to get an accurate quote for your project.

Size or Resolution Limitations– Maximum screen printing size is 16 inches x 16 inches and the minimum size that will be printed successfully is about an 8-point text size.

Advantages– Screen printing is an excellent option for high quantities of items that have a low number of colors, and will yield a durable, long lasting and vibrant print.

To learn more about this process refer to this in depth article.

What Is Screen Printing

Embroidery

Pricing- Embroidery pricing is based on the total quantity of items to be embroidered and the number of stitches in the design. A typical left chest or hat size design will have 5,000 to 12,000 stitches whereas a full back jacket size design will easily push 45,000 stitches. This difference of stitch count will affect the price of both the initial digitization and per-piece cost.

Color Limitations– The pricing for embroidery is not effected by the number of colors, however, embroidery is made up of thousands of stitches and for this reason has certain limitations. Using embroidery to replicate complex gradients and multi-colored outlines is not recommended. Simple designs and color variations produce a more stunning embroidered product.

Size or Resolution Limitations– Maximum embroidery size is 18 inches x 13 inches and the minimum size that can be embroidered clearly is a 12 point text.

Advantages– Embroidery is a classic technique that tends to make the item you are stitching look more upscale. It is also very durable and usually outlasts the item that it is embroidered on.

To learn more about this process refer to this in depth article.

The basics of embrodiery and its production

Heat Transfer Vinyl

Pricing- For the most part Heat Transfer Vinyl does not receive quantity discounts for repeated prints. The nature of this method is such that the press is usually charged at the same price no matter how many repeated prints that are done.

Color Limitations– This method is generally only available for a one-color print or press. Though it is possible to get a two or possibly three color heat transfer vinyl press done, most shops will not recommend or perform this because of the amount of set-up and work that is needed for one print.

Size or Resolution Limitations– Maximum heat transfer vinyl size is 18 inches x 16 inches and the minimum size that can be pressed is a 12 point text.

Advantages– Since this method has very little setup compared to screen printing, it is generally used successfully when used on a large printed area with individual specifics or prints. It is particularly popular when decorating jerseys or team sport wear with individual player names and numbers.

To learn more about this process refer to this in depth article.

Peeling Heat Transfer Vinyl Print

Dye Sublimation Printing

Pricing- In general Dye-Sublimation Printing does not receive quantity discounts for repeated prints. In general it is a bit more pricey than the other forms of printing mentioned here.

Color Limitations– The great advantage of this printing method is the ability to print any color needed, including complex gradients or color variations. Even photograph quality prints are possible using this fast growing technique.

Size or Resolution Limitations– Maximum dye-sublimation print size is usually 18 inches x 16 inches, however, full shirt coverage is also available on demand. The minimum size that can be pressed is a 4 point text or equivalent to a regular print from an ink jet printer at a high resolution.

Advantages– This print methods hold some very important advantages that should be underscored. First, the ability to print at full color with a high resolution quickly beats most other types of printing methods. Next, the low minimum quantity is key, because with limited set-up fees this print type can be performed on a single piece or on multiple pieces. Finally, dye-sublimation results in significant durability and vibrant colors because it actually permanently dyes the fabric with a high quality color. It is supreme in its durability, wash ability and scratch resistance.

To learn more about this process refer to this in depth article.

sports jersey and team uniform printing

Additional Articles

Pete Apo Owner Impact Northwest Picture
Pete Apo

Owner of Impact Northwest

Pete Apo is the owner of Impact Northwest located outside Eugene, Oregon in Creswell.  He has over 17+ years experience in the garment and promotional item printing industry and is founder of the clothing and product line The Rusty Hawaiian. Impact Northwest is a provider of custom screen print, embroidery, dye sublimation and promotional items to Lane County and the surrounding communities.

Pete@Impact-NW.com

The benefits of dye sublimation printing in 2021

The benefits of dye sublimation printing in 2021
Dye Sublimation Printing what are the benefits

The benefits of dye sublimation printing in 2020

By Pete Apo

Dye-sublimation printing is definitely considered the new kid on the block within the printing industry, but thanks to technological breakthroughs it’s growing in popularity fast.  In this article we will cover the benefits of dye sublimation printing in 2021, along with some basics about the sublimation process and the equipment needed.

What is Dye-Sublimation Printing Anyway?

The name may be a bit of a mouthful, but the concept is fairly easy to understand. Dye-Sublimation is the process of using special inks on printed transfer paper to dye a print surface with an image using heat. Its great advantage over traditional printing (at least in the garment industry) is the ability for the print to become a part of the fabric fibers themselves, instead of merely resting on top of the garment surface.

This single benefit results in no worries of the print scraping off or cracking over time. The second main advantage is the ability to use unlimited colors and have no image restrictions. This means that you can have complex gradients and photo quality images with low minimum run requirements and no costly set-up fees. Dye-sublimation may be superior to older, more traditional custom printing methods, but nevertheless you must possess the right equipment and the right skill set for flawless execution.

The Standard Equipment Needed

The standard equipment used in this unique printing method is a specially designed or converted inkjet style printer, special sublimation inks, sublimation transfer paper, a heat press and a sublimation friendly substrate or printing surface.

Special disperse dyes or dye-sub inks are designed to go from a solid state to a gas state at high temperatures. After they are transferred to the print surface they return to a solid state. This permanently dyes the printing substrate resulting in a long-lasting print with vibrant colors.

Sublimation printing requires a printer which is made to print dye-sub inks onto transfer paper. A wide selection of dye-sublimation printers are available in the marketplace, which allow for the perfect fit for any application and budget. Printers are available from 8.5” wide up to 10’ wide.

Transfer paper is also needed, which is made for receiving dye-sub inks and comes in a large variety of sizes to fit your printer. Once you have the design printed on your transfer paper you must lay your mirrored design on the print surface and use a heat press to heat and press the transfer paper on the substrate. Certain time and temperature specifications are required according to the material and ink you are using.

Products able to receive dye-sublimation printing vary greatly and are increasing all the time. These include man-made materials such as nylon, certain plastics and polyester fabrics to name a few. Since this trend of printing has expanded, many polymer treated hard surfaces have become popular as well like aluminum, brass, glass, fiberglass, acrylic, plastic, ceramics and hardboard sheet materials.

sports jersey and team uniform printing

5 Dye Sublimation Printing Benefits in 2020

1. Full Color and High Print Quality

The key benefit of all the benefits of dye sublimation printing in 2021 is the ability to use any color with high-quality resolution. The ink jet printer prints the image transferred, this allows the use of every color in the color spectrum, except white. This includes any type of complex gradients, images and photos, or a combination of all. Using a white solid surface solves the problem of not being able to print white. Wherever the ink is not printed, the surface color of the material will show through. As a result you can print any image with the same high resolution of 150 to 300 DPI+ that can be printed on a home or office ink jet printer.

2. Durability of Print

As mentioned previously the unique process of sublimated printing makes the image one with its substrate or printing surface. This means no cracking, fading or deterioration of the image will occur once it is set into the product. For apparel, this means no worries of print fade after laundering. For non-apparel items you do not need to worry that certain cleaners will erode image durability. If the base material itself can withstand the cleaning agent or environment your print will maintain its original look.

3. Versatility

As this process grows in popularity more and more types of materials can be printed. From custom one- off flip flops, uniforms and socks to large outdoor signage and home decor items, dye sublimation has almost unlimited potential. Here are some items that are now widely used in this industry:

  • Rigid Substrates – Polymer treated, non-fabric items like glass, plastic, fiberglass, ceramics, and aluminum. These are products that aren’t bendable like fabrics.
  • Signage – Easily print on vinyl banners, table cloths and other trade show displays. If you see signs hanging in front of shops or buildings, there’s a good chance that sublimation printing was used.
  • Polyester Fabrics – One of the most popular items to dye sublimate. They are divided into two types: Knit: Polyester products that hang & flow in their natural environment, like apparel, flags, banners, and custom printed table covers. Woven: More durable products such as fabric backdrops and custom tents
  • Home Decor – The dye-sub process is often used by businesses that sell to interior designers. Decor items like ceramic floor tiles are a popular choice for bathrooms, kitchens, restaurants, & more.
  • Photograph Printing – Arguably the best way to produce the highest-quality photographic images on canvas, magnets, and apparel.

4. Low Minimums

Once the image is set up in a graphic design program it can easily be re-printed for high production quantities or for just one-time use. Depending on the complexity of the design it may cost you more for a graphic designer to design and set-up a print than the actual printed item.

5. Ease of Use

As this process has become more popular in recent years, production equipment, product variety and affordability have increased significantly. Printed items that once required a lot of upfront set-up costs can now be achieved with the one time purchase of sublimation equipment. This means that apparel with full color coverage, even over seams, can now be achieved simply.

full color picture printed on computer mouse pad

Conclusion

Sublimation printing can be used consistently over time with great results. Items like mouse pads, coffee cups, face masks, signs and marketing materials, fully custom apparel with overall printing and home decor items will benefit from this type of printing. All of these items can also be washed on a regular basis without fear of distorting their appearance.

Dye sublimation has capabilities way beyond fabric. It leaves countless printing opportunities that come in handy for crafting and business presentations where customization is a bonus.

I hope this information has proved helpful in deciding what type of printing is best for your project. Impact Northwest offers a variety of printing methods alongside of sublimation dye printing including: screen printing, embroidery, vinyl heat transfer and large format ink printing. We would be happy to speak to you about your printing needs.

picture on ladies dress custom printing

Sources:

Pete Apo Owner Impact Northwest Picture
Pete Apo

Owner of Impact Northwest

Pete Apo is the owner of Impact Northwest located outside Eugene, Oregon in Creswell.  He has over 17+ years experience in the garment and promotional item printing industry and is founder of the clothing and product line The Rusty Hawaiian. Impact Northwest is a provider of custom screen print, embroidery, dye sublimation and promotional items to Lane County and the surrounding communities.

Pete@Impact-NW.com