Roll-to-roll sublimation printing process

Roll-to-roll sublimation printing:

Roll-to-roll sublimation printing, an innovative textile printing method, that is becoming increasingly popular due to its adaptability and exceptional outcomes. The Roll to Roll sublimation printing process entails passing a roll of transfer paper through a heat transfer equipment. As the paper passes through the machine, it undergoes the application of heat and pressure, which leads to the sublimation of the dye on the paper and its subsequent transfer onto the substrate.

This technology is frequently employed for printing on textiles, particularly polyester, as well as other substances such as ceramic and metal. The Roll-to-roll technique is highly efficient for large-scale manufacturing as it enables uninterrupted printing eliminating the need for regular paper reloading.

Technology Behind Sublimation Printing Process:

The process starts by printing an image onto a transfer paper using special sublimation ink, which is a solid ink that turns into a gas when heated. 

Your pattern emerges as the print head passes right to the left and back across the paper, laying the ink on the paper in layers over several passes.

Consequently, the heat transfer machine transfers the printed sublimation paper onto fabric under high heat and pressure. Both undergo heating to temperatures ranging from 200 to 400 degrees Fahrenheit using a heat press. 

The heat transfer machine presses sublimation paper and fabric between rolls, converting solid dye directly into gas without liquid stage. The heat, coupled with pressure, causes the dye to penetrate the interior of the fabric, creating a permanent color bond. After removing the heat, the dye returns to a solid form, and the process is complete.

The process results in a vibrant, durable, and long-lasting image that is embedded within the fibers of the fabrics. As colors penetrate the substrate, rather than simply sitting on the fabric’s surface, images remain vibrant even after multiple washings.

Dye-sublimation printing is suitable for a wide range of fabrics, including Polyester, Nylon, and Lycra. It is widely used for printing flags, banners, sportswear, and other items that require bright and bold colors.

The process is eco-friendly, as it uses no water and the ink is free of harmful chemicals.

How Does Sublimation Printing Works?

Step 1: Ready Your Design:

At first, create a design according to the buyer’s requirements. A design developer utilizes graphic software like Adobe to create colorful designs primarily using the CYMK color model.

Step 2: Printing:

The mirrored digital file is printed on specially coated paper, also known as heat transfer sublimation paper. The pattern emerges as the print head moves, applying ink in layers over multiple passes from right to left.

Step 3: Fusing or Heat Transfer:

Printed sublimation paper is then transferred onto the fabric under high heat and pressure using a heat transfer machine. The heat transfer machine presses sublimation paper and fabric between rolls, converting solid dye directly into gas without liquid stage. The heat, coupled with pressure, causes the dye to penetrate the interior of the fabric, creating a permanent color bond. After removing the heat, the dye returns to a solid form, and the process is complete. Since colors embed in the substrate, not just on the fabric’s surface, images won’t fade or crack after multiple washings.

Steps in Roll-to-roll sublimation printing process:

Step 1: create sublimation designs:

To initiate the roll-to-roll sublimation printing process, the initial stage involves generating a digital image through the utilization of computer design software. Select design software that is appropriate for your specific requirements and level of expertise. Common options include Adobe Photoshop, Adobe Illustrator, CorelDRAW, as well as cost-free platforms like as GIMP or Inkscape. Calculate the dimensions of your design by considering the size of the substrate and the capabilities of the printing machine. Roll-to-roll printing facilitates continuous printing across a wide surface, accommodating designs as long as the substrate roll.

Step 2: Printing Setup:

Insert the sublimation transfer paper into the printer. Ensure that it is loaded accurately in accordance with the printer’s requirements.
Modify printer configurations, including paper type, print quality, and color management, to align with your design and substrate.

Step 3: Print Design:

Imprint the design onto the sublimation transfer paper. Make sure to print the design in opposite (mirror image) to guarantee proper orientation when transferring it onto the substrate. Oversee the printing process to detect any problems, such as inconsistencies in color or alignment. This printer utilizes sublimation inks. These inks uniquely sublimate, transitioning directly from solid to gas without passing through a liquid phase.

Step 4: Roll-To-Roll heat transfer:

The transfer paper with sublimation inks and fabric enters a heated roller press. The paper moves through heated rollers, sublimating the inks into gas that permeates the fabric’s fibers. Following the heat exposure, the fabric’s pores open, and upon applying pressure, the ink cools and solidifies. Additionally, this process embeds dye into fabric, creating vibrant, integrated colors and designs, unlike traditional surface printing methods. The ink undergoes a direct transition from solid to gas without becoming liquid, similar to dry ice. This conversion is initiated by heat and regulated by pressure.

Advantages of Roll-to-roll sublimation printing:

1. Stunning designs.
2. High definition prints.
3. Colorfast.
4. Durable.
5. Resistant to fading or cracking.
6. Jumbo roll up to 3000 meter.
7. Mass production.

Applications of Roll-to-roll sublimation printing:

The Roll-to-roll Sublimation Printing process is a versatile and cost-effective way to create lasting, high-quality prints on different surfaces. The applications of Roll-to-roll sublimation printing are-

1. Fashion.
2. Sportswear.
3. Home Textiles.
4. Indoor soft signage.

References:

1. How to print Fabrics by using DTF (Direct-To-Film) printing process?
2. Digital Textile Printing Process – Step By Step Explanation
3. Technology Behind the Digital Textile Printing Machine
4. How to Print a T-Shirt on Direct to Garment (DTG) Printer
5. https://www.subli-star.com/sublimation-printer/