Sublimation Vs. Screen Printing

Ever looked at a cool custom t-shirt and thought, "I wish I could make that"? Well, guess what—you absolutely can! Today, we'll look at two amazing ways to bring your creative designs to life: screen printing and sublimation. 

First, let’s discuss the sublimation and screen printing processes.

Screen printing helps you to create personalized designs using a sophisticated stencil system. To print, you need to push plastisol ink(screen printing ink) through a mesh screen and onto the fabric to create bold, vivid designs!

On the other hand, dye sublimation printing is like something out of a sci-fi movie—it turns ink particles into a gas that bonds well with polyester fibers. This gas is known as a sublimate, and it bonds with the polyester at a molecular level by solidifying after penetrating the fibers in gaseous form.

Here, you will use a heat press, sublimation transfer paper, sublimation printer, and ink to create your customized designs. You can find these materials in your local craft stores or legitimate online retail stores.

Now, let’s look at some detailed differences between sublimation and screen printing.

Screen printing results in thick layers of ink sitting on top of the fabric. The colors are vibrant, and there's something incredibly satisfying about that slight texture you can feel on a freshly screen-printed design! Plus, screen printing can handle specialty inks like metallics, glitter, and even puff inks that rise from the fabric—talk about making a statement!

Dye sublimation takes your DIY printing experience to a whole new level—like having a high-definition photo printer for fabric! The sublimation ink becomes one with the fabric, maintaining the material’s original drape and flexibility. Your sublimation designs will be completely smooth to the touch!

Material compatibility is a game changer when choosing between these methods. Screen printing works on virtually any fabric! Cotton, polyester, blends, even canvas and wood. Its versatility is fantastic if you want to offer a wide range of products for your DIY businesses.

Sublimation, however, is a bit more selective about what it can work with. It needs polyester or polymer-coated materials to work its magic. Yes, it’s a limitation but don’t let that hold you back, cause when sublimation finds its perfect match, the results are spectacular!

Screen-printed designs are remarkably durable when you print as required. The plastisol ink bonds to the fabric's surface and creates a strong print that can withstand significant wear and tear. However, screen-printed designs may eventually start to crack or peel in areas subjected to repeated stretching or friction.

Sublimation presents a fundamentally different durability profile. The process involves the ink becoming part of the fiber structure at a molecular level—only when used on polyester or polymer-coated materials. Sublimated designs often maintain 100% of their visual clarity and color intensity for the entire lifespan of the garment.

Screen printing is more effective when you're dealing with bulk orders. Once you've your print screen set up, you can print dozens or even hundreds of the same designs. The more you print, the more cost-effective it becomes—it’s economy of scale at its finest!

Sublimation, meanwhile, is the king of customization and small runs. There's no setup cost for each design, so you can print one-offs and small batches without breaking the bank. The dye sublimation two-step process, printing on transfer paper and then applying heat, makes it a less efficient process for large-scale production.

Screen printing is not cost-effective for small runs since the setup costs can be high. Screen printing is typically more expensive than sublimation printing due to the amount of labor involved and materials used.

Therefore, sublimation printing is often better for smaller runs, despite the larger upfront costs for equipment. The sublimation prints also require less maintenance over time, promising a greater return on investment than screen printing.

Also, although screen printing equipment may have cheaper initial costs, stencil creation and the need for frequent cleaning end up costing more in the long run.

Both sublimation printing and screen printing have an impact on the environment. However, screen printing has more of a negative impact due to the ink run-off and harsh, non-biodegradable ingredients that must be used along with it.

For example, Plastisol inks commonly used in the screen printing process are known to release  VOCs (volatile organic compounds), which are known to seep into the ground and contaminate drinking water sources. All that while sublimation printing has almost no run-off.

On the other hand, sublimation printing produces relatively less waste than screen printing because the ink is infused into the material. It also has a waterless dye cycle, minimizing water wastage and forever chemicals seeping into the ground.

So, how do you choose? Well, it's all about matching the method to your needs. Consider screen printing if:

Sublimation is best if:

Let’s look at the pros and cons of screen printing and sublimation:

From my experience, sublimation offers unmatched color vibrancy on polyester mugs and T-shirts. Invest in a printer like the Epson SureColor for the most vibrant prints if you're unsure what to start with.

Also, mastering the heat press settings is key. Beginners should start with preset templates to avoid errors. It is also the most cost-effective method when it comes to making small custom-made designs on a variety of surfaces.

On the other hand, screen printing is great for large batches, making it ideal if you want to make a bulk order. For example, if you are running a DIY decor small business, it would be more economical to use screen printing.

It is also worth noting that since sublimation is best for polyester and other polymer-based materials, DIY common materials like cotton may need to rely on screen printing for premium results. Generally, these methods also last longer if used on the respective, ideal material.

However, small businesses using sublimation to print custom items may see an increase in profit due to reduced production waste. Meanwhile, a screen printing business could witness greater success when mass-producing band merchandise since they will be capable of doing it at a lower cost per unit. Thus, when it comes to the most affordable option, it depends on your project.

Also, although sublimation printing generally has a less negative environmental impact due to its minimal waste, screen printing can be eco-friendly when used with water or soy-based inks. Search for certifications such as OEKO-TEX for your inks. You can also reuse screens instead of discarding them after every project, where possible of course, and opt for organic, biodegradable cleaning agents.

• Photo Emulsion: A light-sensitive coating applied to screens, allowing specific areas to harden when exposed to light and creating a stencil for screen printing.
• Sublimation: A printing method where dye turns into gas when heated, bonding permanently with polyester fabric or specially coated materials.
• VOCs (Volatile Organic Compounds): Harmful chemicals released during the curing process of certain inks, contribute to air pollution.
• Plastisol Ink: A commonly used ink in screen printing made from PVC particles suspended in a plasticizer, known for durability but less eco-friendly.
• Polyester Fabric: A synthetic textile material required for sublimation printing, often chosen for its durability and vibrant color retention.

With the two methods of DIY screen printing at home covered, let's wrap up this exciting journey of DIY printing! With your love for the traditional charm of screen printing, you can now bring your creative visions to life. Starting with the simple embroidery hoop method, you can create beautiful custom designs without breaking the bank. And when you're ready to level up, the photo emulsion technique awaits. Happy printing!