Dye Sublimation Printing: For Permanent, All-Over Designs

Dye sublimation is a cutting-edge printing process that creates stunning, permanent and photo-realistic designs that become part of the fabric itself. Unlike other methods that print a layer on top of the material, sublimation uses heat to turn solid dye into a gas, which then permeates and bonds with the polyester fibres of the garment. The result is a print with absolutely zero texture that cannot crack, peel or fade over time.

This technique is the secret behind the vibrant, edge-to-edge designs often seen on professional sportswear. It allows for complete creative freedom, transforming a plain white garment into a bespoke piece of art with unlimited colours and intricate detail.

When to choose dye sublimation

Dye sublimation is the ultimate choice for high-performance apparel and items requiring maximum visual impact. We recommend this process for:

• Technical sportswear: As the print doesn’t block the fabric’s pores, it is perfect for breathable, moisture-wicking running vests, cycling jerseys and team kits. Our Custom Running & Sports Shirts and Custom Running Vests are ideal canvases for this technique.
• All-over prints: Sublimation allows for printing across the entire garment, including seams and sleeves, for a seamless, fully customised look.
• Absolute permanence: For designs that must endure the harshest conditions and frequent washing without any degradation, sublimation is the most durable printing method available.
• Short runs & on-demand: With no minimum orders, it is perfect for creating individual samples or small batches.

 

The sublimation process

1. Printing: Your design is printed onto a specialist transfer paper using sublimation inks.
2. Positioning: The transfer paper is carefully positioned on the (typically white) polyester garment.
3. Heat Press: The garment and paper are placed in a heat press. The combination of high temperature and pressure turns the ink into a gas, which infuses into the polyester fibres.
4. Cooling: The garment is removed and cooled, with the design now permanently part of the fabric.

 

Limitations and considerations

• Fabric requirements: Dye sublimation only works on 100% polyester or high-polyester content fabrics. It is not suitable for natural fibres like cotton.
• Garment colour: The process works best on white or very light-coloured garments, as the sublimation dye blends with the fabric colour.
• White crease marks: For all-over prints, small white marks or creases may appear around seams (like armpits) where the ink cannot reach. This is an unavoidable part of the process.
• Black colour: Achieving a deep, true black can be challenging, as the ink saturation is limited. The result may be a very dark grey or charcoal.

 

Care instructions

To maintain the vibrancy of your sublimated garments, wash them inside out on a cool cycle and avoid tumble drying.

 

Ready to create a truly bespoke piece of sportswear? Contact our team to learn more about our dye sublimation capabilities.