Sublimation Apparel Printing: The Basics for 2022

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Sublimation Apparel printing:

Just when think you’ve covered all your printing bases — screenprinting, DTG — someone asks you about sublimation apparel printing. You might not know what it’s called, but you can’t walk into a retailer without seeing an example of it. It’s a printing method that provides all-over coverage, in full color.

In a nutshell, sublimation printing uses heat to transfer the dyes onto the fabrics. There are two ways to do this: one is to print onto a transfer paper and then transfer the image to the fabric using heat and pressure. The second involves printing the image directly onto the fabric. But either way, you’re looking at transferring the dyes into the polyester molecules using a combination of time, temperature, and pressure. With dye sublimation, the result is a virtually permanent full-color high-resolution print that won’t crack, fade or peel under normal conditions. If you’re looking for color saturation, you’re looking for dye sublimation printing.

Unlike screen printing, where one color is added at a time, with sublimation printing, all colors are printed at the same time so there’s no risk of the colors not lining up or running. And as we may have mentioned, sublimation printing is the only way to go, if you’re trying to get that all-over printed look.

Image above: Epson SureColor® F6070

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Offset vs. Digital Sublimation Printing

There are two types of sublimation apparel printing: Offset and Digital. The differences between the two can be simplified to a single word: volume. Offset sublimation requires a pretty hefty investment – the machinery alone can cost up to $1 million and you’re looking to do print runs of between 5,000 – 10,000. So if you don’t have a cool million hanging around, and you’re hoping for a print run under 500 pieces, then you’re looking at digital sublimation, which will give the saturated all-over print look, without having to invest quite as much capital.

Image above: from Epson’s Digital Sublimation fashion show

1910 SubliVie Adult Polyester Sublimation T-Shirt Catalog

Image above: SubliVie 1910 Adult Polyester Sublimation T-Shirt is soft, lightweight, and is quite literally, made for sublimation.

Direct to Garment Printing (DTG) vs Sublimation

While both DTG and digital sublimation use inkjet printer technology, the processes and results are quite different. The first big difference you’ll notice between DTG and sublimation is going to be your garment choice. DTG is the choice for 100% cotton fabrics, while Sublimation only works on polyester garments (sublimation needs a polymer-based surface). Both processes will work on blended fabrics, but the result will be a little washed out and faded.

But that’s only the beginning. The entire chemistry behind the two processes is different. I’ll spare you the Chem 101, but basically, the DTG process is relying on surface adhesion, while with sublimation, there is actual molecular bonding taking place. (The dye actually begins as gas before becoming a solid!)

Sublimation Apparel Printing Perks

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  • You can print a highly detailed photographic image on nearly any polyester fabric.
  • You can print on textiles prior to the assembly of the garment for all-over coverage
  • Many polyester fabrics provide moisture-wicking capabilities making your garment perfect for high-performance sports ware.
  • There is no feel, which makes for a soft hand.
  • Perfect for full-color design on light textiles
  • Extensive color options

L1610 SubliVie Juniors Polyester Sublimation T-Shirt Catalog

Image above: SubliVie L1610 Juniors Polyester Sublimation T-Shirt is perfect for sublimation apparel printing

When you’re ready to take a leap into the world of sublimation apparel printing, check out our sublimation apparel category. If you don’t see what you are looking for, let us know. And we’ll help you get started on your sublimation journey!

What is DTG Printing: When, Why, and How in 2022

What is DTG Printing? Short for Direct-to-Garment, DTG printing is a method of printing designs directly onto t-shirts and textiles using a modified ink printer.

Custom DTG Printing

Brother DTG Printer

Direct to Garment printing is a direct descendant of inkjet printing. That means no screens, no mess, no thick plastisol ink–yet great detail and stunning color possibilities. How it works is a t-shirt is loaded onto the machine, and your design is printed directly onto the shirt using specially formulated water-based inks. The design is then heat set using either a heat press or a tunnel dryer. In the same way that your inkjet printer can print extremely detailed images, a DTG printer is able to produce photo-quality images on shirts that still have a soft feel.

Custom DTG Printing

No color limitations with DTG Printing means you can print what you want without the price going up. Photo courtesy of Behind the Blank

Sounds great, right? Well, Direct to Garment printing does have its limitations. Specialized ink means it’ll end up costing a little more. It’s also a lot slower than screen printing (think of standing in front of an inkjet printer and waiting for a piece of paper to come out), so labor costs are higher as well. And the printable area is a little smaller, too.

So with so many factors to consider, the real question is when to use Direct to Garment and when to screen print. The basic formula is if you’re printing a multi-colored and detailed design with less than 50 shirts, Direct to Garment is the more efficient and cost-effective choice. Once you start hitting quantities over 50, then screen printing becomes the faster and cheaper option. DTG is also the go-to option if you’re looking to print a photo-realistic image.

Custom DTG Printing

Print your illustrations right onto a shirt with DTG Printing

When printing DTG, the fabric content of the garment is by far going to be the main factor to consider when choosing which shirts to use. Lots of printers insist on going with only 100% cotton (like the Cotton Heritage MC1040 and the gildan 5000 ). We recommend going a step further and choosing ringspun cotton (like the Next Level 3600 or Tultex 290), which is much softer and smoother–and thus prints better. You could also choose an organic cotton shirt, which is great for marketing.

In general, screen printing is going to be a better choice for blended t-shirts if you’re looking for vibrant colors. This is because DTG Inks are best absorbed by 100% cotton, and the color won’t take as well to man-made fibers. However, if you’re looking for more of a subdued print with vintage-style faded colors, DTG could be the perfect choice for your design. White blended shirts print very well, but if you’re using anything other than that we suggest consulting with one of our print reps to be sure there won’t be any issues.

Next step–generating your custom DTG print quoteblankstyle.com is your one-stop shop for all of your blank and printed apparel needs!

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Direct to garment, straight from Bryson’s brain and onto custom shirts

Alabama artist Bryson Thurston was kicked out of his high school art class. Now he’s a self-made, full-time artist, known for his bright, poppy colors, whimsical characters, and uplifting spiritual themes. Bryson has been using Blankstyle.com for a little over a year now, printing his colorful illustrations onto equally colorful hoodies and sweatshirts with direct to garment (DTG) printing.

Artist Bryson Thurston surrounded on a river bank by his whimsical art

“I love seeing people wearing my designs and the reactions they get! 

I use my custom printed shirts to promote my art and people just love wearing it! It makes people so happy!”

What is direct to garment shirt printing vs screen printing?

You probably already know the basic idea behind screen printing. Simply put, a design is added to a garment in layers using a separate screen for each color in the design. But, when producing designs with many colors, more layers/screens are needed. When more screens are needed, the production cost increases.

In contrast, DTG works much like your at-home printer, printing the complete design in one pass. Because of this one-step process, DTG t shirt printing can be more cost-effective for our customers like Bryson who want to create apparel with very colorful designs.

Artist Bryson Thurston wearing his art as Direct to Garment print on Cotton Heritage MC1082 Vintage White T Shirt
Artist Bryson Thurston wearing his art as Direct to Garment print on Champion T137 Raglan Baseball Tee

(Bryson is wearing Cotton Heritage MC1082 and Champion T137 above.)

We’re all here for a short time yet we can plant so many seeds in our lifetime.

I use my art to plant seeds of joy, love, healing, and hope, among many others! Those seeds have the potential to grow into something far more beautiful than we ever imagined!

Bryson’s favorites for custom printed sweatshirts?

“I really like the brands Cotton Heritage and Independent Trading Co. They’re both of superb quality and worth every penny.”

Bryson used direct to garment printing on the Cotton Heritage U2690 hoodie and the Independent Trading Co PRM3500 crewneck sweatshirt, both shown here.

Artist Bryson Thurston wearing his art as Direct to Garment print on Cotton Heritage U2690 Sponge Fleece Hoodie
Man on bike wearing beanie and Bryson Thurston art as Direct to Garment print on Independent Trading Co PRM3500 Crew Neck Sweatshirt

Is direct to garment printing right for you?

DTG printing is great for large designs with many colors and is great for printing photographic images onto apparel. However, it’s not without its limitations. Most importantly, DTG must be used with 100% cotton or 100% cotton-faced fabric. Because the ink used is water-based, it cannot adhere to unnatural fibers like polyester.

Which is better, DTG or screen printing?

Learn more about the pros and cons of both printing options HERE. Still have questions? Reach us via chat or by calling 866-792-5265. Our team is available to answer any of your custom printing questions!

Show Bryson some love!

Cotton Heritage: A Lesson in Entrepreneurship

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Some people seem to have entrepreneurship in their blood. Neeraj “Mickey” Sachdeva, CEO and founder of Cotton Heritage came by both his entrepreneurial sense and his understanding of textiles honestly.

The Sachdeva family has a strong tradition of working with textiles. Mickey was actually raised in a city, which is considered to be the capital of the knitwear garment industry in North India. And the family business, Roochi Traders, a leading distributor of sportswear and active wear, was founded by Mickey’s father, Vishwa Sachdeva, back in 1982, the year that the Sachdeva family came to the United States.

In a true immigrant success story, Vishwa landed in the US with only $25 in his pocket, and looked to textiles to help provide a living for the family. He started importing fabrics from Japan with the help of some relatives. Then in 1986, when the Japanese yen turned strong, and it was no longer profitable to import from Japan, Vishwa began selling garments to Indian shops in the Los Angeles area. It was a true family business. Mickey’s mother, Prem, would sew from 6 AM to midnight every day, making the clothes that Vishwa would later sell.  Both Mickey and his brother, Vikram (Vik), helped out with the family business when they weren’t busy with schoolwork.

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Mickey was only 14 when the family left India and moved to California, but it didn’t take him long before he jumped straight into American commerce.  First, he took on a newspaper route. Then he got a job washing recreational vehicles. He flipped hamburgers at Wendy’s, and worked as a cashier at Knott’s Berry Farm. He got a job at a General Motors plant and then as a bank teller. He was just a teenager, but Mickey already had had more jobs than most people twice his age. Mickey says that initial work experience was critical to his later success. “It gave me an insight into a lot of different things,” says Mickey. “How to deal with people, how to handle money, how businesses work.”

By 11th grade, Mickey, was anxious to take the jump from working for others to working for himself and so he began pressuring his father to let him take on a bigger role in the family clothing business. “But my dad, a typically Indian father, wanted me to concentrate on my education first,” says Mickey. “I was very persistent and told him I would bug him every day about it. So Mickey was put to the test.  He was dropped off at the Los Angeles flea market with a box of 24 dozen undergarments and told to sell them. Only seventeen, Mickey wasn’t given any instructions about how to make the sales, but he still managed to sell nearly all of the undergarments in the box, and the experience only whetted his appetite for more.

While enrolling in college, Mickey started selling garments out of the family garage. That small business grew and grew until finally a neighborhood complained about the large trucks showing up to the Sachdeva residence on nearly a daily basis. Instead of being defeated, the push out of the family garage gave Mickey the momentum to move to a real warehouse, an 800-square foot space in Santa Fe Springs, California.

Today, the company is based in a 110,000-square-foot warehouse in the City of Commerce, its
headquarters since 1996. The company also has distribution centers in New York and Miami, for a total of 165,000 square feet of warehouse space. A far cry from that initial start in the family garage.girls

And Cotton Heritage still remains true to the Indian heritage of the Sachdeva family. All the goods are manufactured in South East Asia and in other Eastern garment industry hubs. Because they can speak the language and understand the cultures of these countries, it makes it an easy place for the Cotton Heritage brand to be manufactured. Mickey says that these days, his only goal is to make clothes that he wants to wear. That means, using the best yarns and dyes possible and making sure that quality control is top notch.

This commitment to quality means that Cotton Heritage shirts are considered to be one of the best shirts for direct to garment printing. Mickey says that they achieve this by choosing the right quality yarns, knitting them tightly and then by choosing the right dyes and chemical suppliers and enzyme helps the product to create a flat and good surface for printability. They also use an enzyme wash to keep the clothes extremely soft (The enzyme removes all the impurities from the surface of the fabric and gives it a better appearance, surface, and hand feel.