Inkjet Printers. Inkjet printers have become the most popular device for producing digital thermal transfer products.
Sublimation dye transfer can also be applied to large format inkjet printers, such as Roland's. With the heat-sensitive laminating equipment, the images are transferred to the polyester-based film layer for marking and printing on the panels. In addition, they can also be used for the printing of wood products and other specialized materials.
Initially, ink jet transfer products can only be produced using standard inks for desktop inkjet printers. Just like hot wax transfer products, these transfers are done on coated paper and rely on the coating layer being transferred to the final substrate during heating. In the end, however, some companies, such as Sawgrass, have begun to provide sublimation inks that can be applied to desktop and large-format inkjet printers, expanding the thermal conversion capabilities of these printers.
Sublimation inks for inkjet printing are transferred directly to uncoated paper. These sublimation dyes are not activated during the printing process but are carried by a water-based medium and crosslinked to the transfer paper. Dye sublimation is only activated when the image is to be heat transferred to the final substrate. In other words, ink-jet sublimation ink transfer represents the first generation sublimation program.
Inkjet sublimation printing systems are faster than thermal transfer printing equipment. In general, the inkjet system can print 720×720 or 1440×1440 dpi resolution full-color, envelope-size images in 1-3 minutes. The desktop thermal transfer printing system typically features a maximum resolution of approximately 300-400 dpi, which can take twice as long to print a color image of the same size. The difference in print speed occurs because the inkjet printing system simultaneously ejects four colors onto the printing paper, and on the thermal transfer printing system, the processing of each color is independent.
laser printer. The last type of digital printer that produces thermal transfer products is a laser printer (Figure 3). The advantages of laser printers are the fastest desktop office systems. Produces 5-6 envelope-size, full-color prints per minute with a resolution of up to 1200 x 1200 dpi.
In desktop office systems, the fastest transfer device is a color laser printer that prints envelope-size products at speeds of up to 6 pages per minute. Xanté's printer supports sublimation toner printing, as does Sawgrass' new Natura apparel printing system. The toner of the Natura printer can be directly transferred to 100% pure cotton garments without the need for special copy coating.
Conventional color laser printers use dry toner fused to transfer paper. Like other non-sublimation ink transfer systems that use transfer paper, a typical laser transfer image uses heat to transfer the image from the transfer layer to the substrate.
As with inkjet printing systems, sublimation inks can be applied to desktop laser printing systems. The most popular laser printing systems for producing sublimation ink transfer products are the products of Xanté and Minolta-QMS. With these systems, specialized sublimation toners are used to print commonly used, non-coating paper sheets. The image was sublimated directly from the transfer layer to the polyester and polyester coated material.
Laser printing equipment is also the best choice for new image transfer equipment, which makes it possible to print 100% cotton garments without using a polymer-coated transfer layer. The new Natura digital apparel printing system is provided by Sawgrass. The system combines Xanté's Color ScreenWriter laser printer and specially designed Natura toner. These toners are not based on conventional surface toners or sublimation compounds, but use a specialized heat-activated chemical that reacts to the cotton fiber molecules to form a permanent image. This is a soft, durable transfer image.
High-speed color copiers use laser engines used in laser printers, and can also generate toner-based transfer products on coated paper, which is also an option for transfer equipment. But its high price is not the focus we are talking about today.
Digital Printing Application
Now that we understand the basic principles of digital transfer technology, it is time to consider its specific applications. If you are using traditional toner technology (such as traditional inks, toners, wax ribbons, etc.), then you are limited to printing only on light colored garments. This application is also the only choice for equipment associated with polymer coated transfer paper. However, this system configuration may be sufficient to meet those disposable and low-volume clothing print orders, and will also bring larger orders for your regular printing equipment.
In order to be able to produce the largest range of printable products, sublimation ink transfer technology is the path we need to take. Condé and Xpres, for example, provide a full range of solutions for the production of sublimation ink transfers, including digital printers, software, inks, transfer papers, thermal transfer printers and a wide variety of polyesters and coated polyesters. The product - the sublimation ink image can be transferred to it. In the coated sublimation ink products, you will find mouse pads, clocks, cargo ships, decorative metal plates, signs, hangers, name tags, photo frames, tapes, glass and ceramic glasses (see Figure 4), plates , beverage caps, ceramics, and more.
Polyester-coated ceramic cups are one of the most popular products at present, and they can use sublimation inks for image transfer.
However, you do not necessarily only purchase preprinted substrates. Condé's Liquid Stone product allows you to coat virtually any non-porous material so that it can accept sublimation ink images. The coating layer is a water-based liquid polymer, which can be coated with a paint brush, roller or gauze.
In the textile and wear side of clothing, polyester T-shirts, sweatshirts, pillowcases, towels and similar products can receive sublimation ink transfer without the need for a special coating layer. However, 100% polyester clothing is not the most comfortable clothing to wear. Potential customers are more willing to T-shirts are 100% cotton or cotton fiber mixture.
In the initial stage of the sublimation ink digital transfer product, the method of printing the sublimation ink image on the cotton product is to print the sublimation ink onto the polyester coating carrying layer. With this method, you can transfer both the image and the coating layer to the garment. If you are using conventional digital ink for the transfer, this will be as you wish. The only difference between the sublimation ink transfer and the conventional image transferred along the paper coating layer is that the sublimation ink is absorbed onto the coating during the thermal conversion process without being compressed by the surface of the coating and the garment. However, apart from this difference, both methods still result in a hard, glazed feel for the transferred image.
An improved solution is proposed here, which is to make the customer feel comfortable in sublimating the ink-printed garment rather than being as hard as a transfer coating. Three years ago, Hanes Printables launched Soft L`ink style clothing, a t-shirt made of novelty, double-sided materials, and other apparel (see Figure 5). This textile consists of a soft cotton inner layer and a 100% micro polyester outer layer that supports the sublimation ink image without the need for a special coating layer.
Hanes Printables launched Soft L`ink style apparel line to support sublimation ink transfer images. This double-sided fabric has a cotton inner layer that is comfortable for the wearer and a polyester outer layer that receives the sublimation ink.
Focus on costs
The cost of investing in digital transfer technology varies with the type of press and ink. For a complete desktop system with all the equipment, ink, paper, and other unfinished business you need to start, you may have to pay $4,000-8,000. It is important to remember that digital transfer processes have been built on higher-end printers rather than home or office equipment, so if you choose to get such a printer alone, you can plan to pay between $2,000 and $6,000. . If you choose a wide format printing system, you are expected to pay at least 5 times more money than a desktop printer based on the same technology to purchase the corresponding printing press.
The cost of consumables varies greatly depending on the type and size of the press you use, and the corresponding ink system. To examine these costs, the most important method of enlightenment is to consider the costs that they (the manufacturer) invested in each manufacturing process. For example, when producing T-shirts, consumables include ink, carbon paper, and plain clothes. Based on the current supply price, it is expected to pay 3-5 US dollars to produce a printed garment. However, the good news is that the finished product is likely to be sold at a price of $15-20 per item and enjoy 50-75% profit.
Digital transfer profit
The development of new moneymaking opportunities for your screen printing company does not mean that you must pay full attention to technologies that require a lot of money or expand your customer base. The opportunity is: Your existing customers already mean that there is a lot of unopened potential sales revenue in short-lived and special printing needs. By adding digital transfer technology, you can undertake the production business that you once had to give up, and quickly increase the company's business bottom line.
Author: Yang Yunliang
Source: Wins
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