Comprehensive Guide to Sublimation Printing: Process & 113 Expert Insights

The global dye sublimation printing market was valued at $15.00 billion in 2025, with a projected compound annual growth rate (CAGR) of approximately 10.88% each year through 2030. However, with this rapid growth comes an increase in poor-quality sublimation prints, products that crack, peel, or lose their color over time, leading to branding failures.

We are here to help you address these issues with a practical guide to sublimation printing, so you can make informed decisions when choosing sublimation printing over others and before approving your samples or mockups.

At GiftAFeeling, we reviewed over 47 articles on sublimation printing to identify the gaps where important details are often overlooked. While many of these articles explain the basics well, they miss the critical points that really matter in production. Our goal is to provide you with insider knowledge and best practices that will make all the difference in achieving the best results for your promo products with sublimation printing.So instead of writing yet another “Sublimation Printing for Beginners” guide, we decided to share the exact protocols we have followed to print over 1.3 million error-free products in the last five years. We'll walk you through the key steps and processes we use to achieve consistent, top-quality results, every time.

We combined our hands-on experience with millions of sublimation printed products and insights from 113 sublimation experts across the US and Canada to explain why sublimation is the gold standard for corporate branding and where most brands go wrong in their sublimation printing process.

This guide breaks down how sublimation printing actually works in production. You will learn where sublimation performs best, where it falls short, how it compares to other printing methods, and common sublimation printing issues and their solutions.

If you are thinking about using sublimation printing for promotional products, branded merchandise, or corporate gifts, this guide will help you decide if sublimation is the right choice based on material limits, durability, color accuracy, and long-term performance, rather than assumptions or mockups.

Let us dive into what sublimation printing is and how the process works from screen to finished product!

What Is Sublimation Printing, And How Does The Sublimation Printing Process Work?

Sublimation printing, also called dye-sublimation, uses heat and pressure to turn solid dye into gas and permanently embed the dye into polyester fabrics (t-shirts, jerseys, tote bags, pouches, garden flags, mouse pads) or polymer-coated materials such as mugs, tumblers, bottles, coasters, and puzzles.

Sublimation printing is commonly used when companies need full-color branding that won't crack, peel, or fade over time. Dye-sublimation printing typically requires sublimation ink, transfer paper, a heat press, and a compatible inkjet printer. In practice, heat and pressure turn the dye into gas so it bonds permanently with polyester fabric or polymer-coated surfaces. Understanding how the process works helps you decide when it’s the right choice for your promotional products, merch items, and corporate gifts.Here's how the sublimation printing process works step by step:

1. Artwork preparation: First, you need to create the design on a computer as a digital file. It can be a logo, photo, or full-color artwork, generally saved as a vector file, such as AI, EPS, or PDF, or as a high-resolution image like PNG or TIFF.

2. Printing onto transfer paper: Next, a sublimation-compatible inkjet printer prints your custom design onto special transfer paper using sublimation ink.

3. Heat press transfer: In the third step, place your transfer paper on the product you want to apply the design to, then apply heat and pressure for 45–90 seconds, typically at 356–401°F (180–205°C), depending on the material.

4. Final sublimated print: As a result, the ink converts into gas, and the dye moves from the transfer paper into the substrate. Finally, you get a permanent, vibrant print that won’t crack, peel, or fade over time.

Sublimation Printing Pros and Cons

Now that you understand how sublimation printing works, let's discuss the pros and cons of this printing technique.

Pros of Sublimation Printing

Sublimation printing provides several benefits, both in terms of product quality and production efficiency. Below are six key benefits you should know about:

1. Permanent Prints

Sublimation creates permanent, vibrant prints because the dye embeds directly into the polyester fibers or polymer coating. This means the design won’t crack, peel, or add any texture to the product. Apparel brands, sportswear programs, and lifestyle merchandise benefit most, especially where comfort matters. For example, team shirts remain breathable and comfortable even after repeated washing and regular use.

2. Print Durability

Sublimation prints create permanent, vibrant results that won’t crack or peel over time because the dye transfers directly into the material rather than sitting on the surface. In indoor environments, office gifts and home décor promotional items benefit most, such as mouse pads and mugs that continue to look consistent even after months of daily use.

3. Print Comfort

In sublimation printing, there is no layer of ink sitting on top of the fabric because the dye embeds permanently into the polyester fibers. As a result, the finished garment, even in areas with large graphics, feels the same as an unprinted shirt. This matters for fitness apparel, staff uniforms, and event wear. Unlike heat transfer vinyl (HTV), logos do not stick to the skin, harden, or cause friction during prolonged wear.

4. Product Versatility

Sublimation printing is a versatile method suitable for a wide range of products because the process works equally well on polyester fabrics and polymer-coated hard goods. In practice, this allows businesses to use sublimation for apparel, drinkware, desk accessories, and event items.

5. Fast Turnaround Time

In sublimation printing, production can begin as soon as the artwork or design is approved because there are no screens, plates, or drying steps required. In practice, this makes it possible to handle both small orders and bulk orders on the same day. We often see this used for last-minute mugs, event apparel, or onboarding items where deadlines are tight and there’s no room for delays.

6. Reduced Inventory Risk

Sublimation printing simplifies inventory planning by allowing businesses to stock blank products while managing branding and artwork digitally. Because designs are applied only after final approval, there is less risk of holding excess or outdated pre-printed stock. This works well for corporate orders, where a single SKU of white polyester T-shirts can support multiple campaigns, departments, or programs without increasing stock complexity.

Cons of Sublimation Printing

Sublimation printing also has certain limitations. Below are three key drawbacks to consider before choosing this printing method:

1. Limited Material Options

Polyester is key in sublimation printing. The process only works on polyester fabrics and polymer-coated products, which limits the range of usable materials. Fabrics should generally contain at least 65% polyester; below this level, prints appear very faded and take on a vintage look.

2. Light or White Base Required

Sublimation ink is transparent, which means it relies on the base color of the product to accurately reflect the design. As a result, designs printed on dark or colored surfaces may appear muted or be completely obscured. This can be a limitation for brands that require darker garments or products. In such cases, it is often necessary to use a white or light-colored base or switch to alternative methods such as DTF or DTG.

3. UV Fade Risk

Sublimation dye can fade when exposed to prolonged sunlight because the dye is not naturally UV-resistant. For this reason, sublimation printing is less suitable for outdoor signboards, banners, or outdoor gear that remains in direct sunlight for extended periods.

What Can You Sublimate Onto?

You can sublimate onto polyester-rich fabrics, typically 65% or higher, and hard goods with polymer coatings such as ceramics, metals, glass, wood, and certain plastics specifically designed for sublimation. The substrate must withstand temperatures of approximately 375–400°F (190–205°C) and be light or white so the dye can bond properly and reproduce accurate color.

At GiftAFeeling, we produce sublimation-printed products every day across more than 50 different SKUs. Below, we share real products printed in our workshop for corporate programs, so you can evaluate sublimation based on actual finished results rather than theory or generic product lists when planning your next project.Here is a list of products that have been printed in our workshop using sublimation:

1. Custom Sublimation Printed Mug

Custom sublimation printed mugs are often used for office desks, onboarding kits, and conference giveaways.

2. Custom Sublimation Printed Crew Socks

Custom sublimation printed crew socks work well when full-coverage branding is needed on stretch fabric.

3. Custom Sublimation Printed Flip Flops

Custom sublimation printed flip flops are commonly used for summer events and travel programs.

4. Custom Sublimation Printed T-Shirts

Custom sublimation printed t-shirts are preferred when detailed, full-color artwork is required on polyester fabric.

5. Custom Sublimation Printed Beach Shorts

Custom sublimation printed beach shorts are chosen for lifestyle and seasonal promotions.

6. Custom Sublimation Printed Mouse Pads

Custom sublimation printed mouse pads allow edge-to-edge printing with strong color accuracy.

7. Custom Sublimation Printed Coaster

Custom sublimation printed coasters are suitable for hospitality and tabletop branding.

8. Custom Sublimation Printed Tote Bag

Custom sublimation printed tote bags are widely used for trade shows and everyday carry.

9. Custom Sublimation Printed Sports Towel

Custom sublimation printed sports towels are applied in fitness, sports, and outdoor programs.

10. Custom Sublimation Printed Lanyards

Custom sublimation printed lanyards are frequently used for events, conferences, and ID access.

Sublimation Compared To Other Printing Methods

Choosing the right printing method depends on the type of product, the level of detail in your design, and the durability required. Sublimation printing is widely used for creating detailed, full-colour designs on polyester or polyester-coated products; however, it is not always the best option for every material or application.The comparisons below show how sublimation printing differs from other common printing methods, helping you decide which method is best suited for your branded merchandise, promotional products, or corporate apparel needs.

1. Sublimation vs Screen Printing

Sublimation Printing	Screen Printing
Materials: Works only on polyester fabrics and polymer-coated products.	Materials: Works on natural fabrics such as cotton, linen, and rayon, as well as many blended materials.
Print quality: Delivers vibrant, photo-quality colors and smooth gradients, ideal for detailed brand visuals.	Print quality: Produces bold, solid colors; fine details and gradients depend on screen setup and ink layering.
Durability: Dye is permanently embedded into the substrate, resisting cracking or peeling through regular wash and wear.	Durability: Thick ink layers hold up well but may crack or fade over time with heavy use.
Hand-feel: Feels soft and breathable with no raised texture on apparel.	Hand-feel: Ink sits on the surface, creating a noticeable texture on fabric.
Fast turnaround: Minimal setup enables quicker production.	Setup/turnaround: Requires screen creation and alignment, which can increase production time.
Cost efficiency: More efficient for small to medium production runs, especially with multi-color designs.	Cost efficiency: Becomes cost-effective for large-volume production with limited color designs.

2. Sublimation vs DTF Printing

Sublimation Printing	DTF Printing
Process: Uses heat and pressure to turn dye into gas, bonding it directly into the fabric or coated surface.	Process: Prints designs onto a transfer film, which is then heat-pressed onto the product surface.
Materials: Best suited for polyester fabrics and polymer-coated products.	Materials: Works across cotton, polyester, fleece, nylon, and blended fabrics.
Print quality: Produces vivid, edge-to-edge color with consistent brand reproduction.	Print quality: Handles fine details and gradients well on light-colored fabrics.
Durability: Extremely durable since ink bonds permanently with the substrate.	Durability: Good durability, though prints may fade faster with frequent washing.
Hand-feel: No added texture; maintains the original fabric feel and breathability.	Hand-feel: Soft and flexible, but the printed layer is slightly noticeable on the fabric.

3. Sublimation vs DTG Printing

Sublimation Printing	DTG Printing
Materials: Only suitable for polyester fabrics and polyester-coated products.	Materials: Mainly suitable for cotton and cotton-blend garments.
Base color: Limited to white or light-colored materials.	Base colour: Produces strong prints on both light and dark fabric colors.
Print quality: Shows small details and smooth color changes clearly on light-colored items.	Print quality: Creates bright, full-coverage color with good detail on garments.
Durability: Very durable because the ink becomes part of the material and does not crack or peel.	Durability: Durable, but prints may fade faster with frequent washing.
Hand-feel: No texture; the fabric feels the same and stays breathable.	Hand-feel: Soft feel, though the printed area is slightly noticeable on the fabric.

Sublimation Printing Troubleshooting

Sublimation printing issues often come from small changes in heat, time, pressure, moisture, color management, or material quality. When these variables shift, ghosting, fading, and branding color inaccuracies occur.Below are the 10 most common sublimation printing problems along with practical solutions:

1. Faded or Washed-Out Colors

When sublimation prints look light, blacks appear gray, or brand colors lack vibrancy, the most common cause is insufficient heat or press time. Start by increasing the press temperature slightly, usually by 5–10°F (3–6°C), and run a test print. If the print still looks weak, extend the press time by 5–10 seconds. If heat and time are correct, check that the correct ICC profile is being used for your specific ink, paper, and printer combination. Also confirm that the blank itself is suitable for sublimation, as low polyester content or poor coatings will prevent the dye from fully bonding, no matter how good your settings are.

2. Color Shift (Brand Blue Printing Purple or Teal)

If colors look accurate on screen but shift noticeably on the finished product, the issue is almost always related to color management. This usually happens when the wrong ICC profile is applied or when both the design software and printer driver are managing color at the same time. To fix this, ensure that only the design software manages color and that the printer driver color management is disabled. Apply the exact ICC profile designed for your ink and paper, and use Relative Colorimetric with Black Point Compensation for logos and brand colors to keep shifts to a minimum.

3. Sublimation Banding or Lines

Banding appears as horizontal lines across the print and is most noticeable in gradients or large solid areas. This problem typically starts at the printer, not the heat press. Begin by running a nozzle check to confirm that all nozzles are firing correctly. If you see gaps, perform a cleaning cycle, but avoid repeated cleanings back-to-back, as this can introduce air into the system. Once nozzles are clear, run a head alignment and make sure the printer is set to its highest print quality or resolution for production jobs.

4. Ghosting in Sublimation (Shadows or Double Images)

Ghosting shows up as a shadow or double image and is usually caused by movement or moisture during pressing. The most effective fix is to secure the transfer paper firmly to the substrate using heat-resistant tape at multiple points so nothing can shift when the press closes or opens. Pre-pressing the blank for 5–10 seconds helps remove trapped moisture, which can create steam and push the paper out of position. Always replace protective paper between presses, as reused sheets can hold moisture. If needed, slightly increasing pressure can help prevent micro-movement during transfer.

5. Blurry or Bleeding Edges

When edges look soft or colors bleed beyond the design, the print is usually being over-pressed. This means too much heat, too much time, or too much pressure. Start by reducing press time slightly, then lower pressure if needed. Using the correct paper also matters; tack paper helps hold transfers in place on textiles and reduces dye movement. Reducing these variables allows the dye to stay where it should be, rather than spreading out.

6. Moisture Spots or Mottling

Random light or dark patches are almost always caused by moisture in the paper, blanks, or environment. The fastest fix is to pre-press the substrate for 5–10 seconds to drive out moisture before applying the transfer. Store sublimation paper in sealed bags, preferably with desiccants, and avoid leaving it exposed overnight. Keeping shop humidity between 45–60% greatly reduces moisture-related defects and keeps results consistent throughout the day.

7. Uneven Transfer or Cold Spots

If parts of the product look lighter or darker than others, the heat press is not delivering even heat or pressure. Use an infrared thermometer to check temperature across the platen and confirm there are no cold spots. Adjust pressure so the entire surface makes full contact, and use pressing pillows or pads where necessary to compensate for uneven surfaces or seams. Consistent contact is essential for even dye transfer.

8. Press Marks or Scorching

Glossy boxes or yellowing on polyester are signs of excessive heat or pressure. Lower the temperature slightly and reduce pressure to prevent fibers from being crushed or overheated. Always use clean butcher paper or protective sheets between the platen and the garment to shield fabrics from direct contact. These small adjustments usually eliminate press marks without affecting color quality.

9. Black Printing Brown / Reds and Oranges Looking Dull

When blacks appear brown and warm colors lack saturation, the sublimation dyes are not fully activating. Increasing temperature within safe limits is usually the first fix, followed by extending press time slightly. If the issue persists, the ICC profile may have a low total ink limit that restricts color density. Switching to an ICC with better ink coverage often restores depth and vibrancy, especially for brand-critical colors.

10. Substrate Issues

Not all sublimation problems are caused by settings. Using the wrong materials will limit results no matter how well the process is controlled. Tack paper works best for apparel, while standard paper is more suitable for hard goods. Sublimation ink should always be stored sealed and used before expiration. Blanks should have consistent coatings and at least 75% polyester content for bright, vivid images. Poor substrates are one of the most common causes of inconsistent production results.

Common Sublimation Heat Press Settings by Material

Different materials require different heat press settings in sublimation. The table below shows commonly used temperature, time, and pressure ranges for the most frequently sublimated materials.

Material	Temperature	Time	Pressure
Polyester apparel	385–405°F (196–207°C)	45–60 sec	Medium
Ceramic mugs	385–400°F (196–204°C)	180–210 sec	Medium
Stainless steel tumblers	365°F (185°C)	60–90 sec	Medium
Aluminum photo panels	385–400°F (196–204°C)	60–90 sec	Firm
Hardboard / MDF	380–400°F (193–204°C)	60–90 sec	Medium–firm
Glass	375–400°F (191–204°C)	180–240 sec	Medium

FAQs

Is sublimation printing good quality?

Yes. Sublimation printing produces high-quality, durable results because the dye bonds directly with polyester fibers or coated surfaces. Prints don’t crack, peel, or fade easily, making them ideal for corporate apparel, mugs, and promotional products. For best quality, use white or light-colored substrates with at least 65% polyester content.

What is needed for sublimation printing?

Sublimation printing requires a sublimation printer with sublimation ink, sublimation paper, a heat press, and compatible substrates such as polyester apparel or coated hard goods. Color accuracy also depends on using the correct ICC profile and stable press settings, typically around 380–400°F, to ensure consistent results for branded merchandise.

Can you wash sublimation shirts?

Yes, sublimation shirts can be washed repeatedly without damage when cared for properly. Because the dye becomes part of the polyester fibers, prints remain colorfast. For corporate apparel, wash cold, turn garments inside out, and avoid bleach or high heat drying to preserve color vibrancy and fabric integrity.

What are common sublimation mistakes?

Common sublimation mistakes include incorrect heat or time, wrong ICC profiles, moisture in blanks, and using low-polyester fabrics. These issues cause fading, ghosting, or color shifts. In corporate production, skipping test presses and ignoring humidity control are frequent errors that lead to reprints and inconsistent branding across promotional products.

Why is my sublimation faded after washing?

Sublimation prints fade after washing when heat, time, or material compatibility is incorrect during pressing. Low polyester content, insufficient temperature, or harsh wash cycles can weaken results. For corporate apparel, ensure at least 65% polyester, press near 385–400°F, and wash cold to maintain long-term color durability.

Can you use 100% cotton shirts for sublimation?

Standard sublimation does not work well on 100% cotton because the dye requires polyester to bond permanently. On cotton, prints appear faded and wash out. For corporate use, either choose polyester blends or use specially coated cotton shirts designed for sublimation to achieve acceptable branding results.

How to get sublimation colors more vibrant?

To achieve vibrant sublimation colors, use high-quality sublimation ink, correct ICC profiles, and bright white substrates. Press within the recommended temperature range, usually 380–400°F, and confirm adequate time and pressure. For corporate gifts, higher polyester content and consistent press calibration significantly improve color depth and clarity.

How do I troubleshoot common sublimation printing errors?

Troubleshooting sublimation printing starts with identifying the symptom, then checking heat, time, pressure, moisture, and color management. Run nozzle checks, confirm ICC profiles, and pre-press blanks to remove moisture. This systematic approach helps corporate teams reduce scrap, avoid reprints, and maintain consistent branding across large merchandise runs.

Can I use sublimation printing on dark-colored fabrics?

Sublimation printing does not work effectively on dark-colored fabrics because the dye is transparent and relies on a light base. On dark garments, colors appear muted or invisible. For corporate apparel, sublimation is best suited for white or light-colored polyester, or use alternative decoration methods for dark fabrics.

How does sublimation printing compare to heat transfer vinyl?

Sublimation printing offers a softer feel and greater durability than heat transfer vinyl because the design becomes part of the material. HTV sits on top and may crack or peel over time. For corporate merchandise, sublimation excels on polyester, while HTV remains useful for short runs or cotton garments.