6 Common Sublimation Printing Problems & How to Fix Them

Summary

Sublimation printing is a unique printing technique that works exactly how one might think it would. The design is transferred to the material in a gaseous state, which then solidifies instantly. 

It is also very easy to learn and offers a wide range of colors to work with, making sublimation printing ideal for rigid surfaces and vinyls. But like every printing solution, it also has its own set of setbacks and roadblocks. For instance, sometimes transfers come out dull or blurry, or there are shadow effects in the transfer, and so on.

However, these are not very complex issues, just some common sublimation printing problems that can be easily resolved with the right approach and understanding. If you also want to enter the sublimation printing market or expand your printing capabilities with this method, here are some common printing problems. The blog will also discuss relevant sublimation printing solutions to tackle the said issues. 

Next, you will also learn about some preventive maintenance tips for the printers to further mitigate the issues from occurring.

1. Image Ghosting

Problem: 

This issue looks like a second image, sort of like a double print, a little off to the side of your image. It is basically two copies of your sublimation print on the surface that happens due to a slight oversight when printing.  

Causes: 

This occurs when the sublimation transfer paper shifts even slightly during opening or closing the heat press. This is not the only reason, sometimes it can insufficient adhesive, or excessive moisture, or fabric shrinkage while the ink is not fully dried that causes image ghosting.  

Solution:

You can tape down the hard material substrates to the sublimation paper. You can or use thermal tapes for this purpose. If you’re printing on fabrics, use adhesive spray to keep the paper intact. But, make sure that you remove the transfer paper immediately after pressing. 

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For sublimation, avoid using an auto-open press. Why? Because they tend to open too fast, which. may cause a shift in the paper if you haven’t taped it well. the paper well.

2. Less Vibrant Transfers

Problem: 

Sublimation printing is known for its vibrant prints, but sometimes, the result is exact opposite. The transfers do not come out as vibrant as expected. This is generally due to lack of knowledge on how to use the particular sublimation printer. 

Causes: 

Sublimation paper has two sides (bright white and off white) and using the wrong one often leads to this issue. Like in sawgrass virtuoso SG400, bright side will load face down in the tray otherwise it might not work well. Similarly other printers come with their own set of complications like taking time to load inks or temperature/pressure issues. 

Solution: 

Unlike a lot of issues, this is one is fairly easy to resolve. Like in case you have just installed new inks, you might need to run a few copies before you the actual print. Or, in some cases, make sure that the temperature, time, and pressure is exactly what is recommended, so you get optimal results. 

Don’t be afraid of trying and testing, in case you are introducing a new product. Run a few test blanks before trying on an actual products until you get all the variables until you get them right.

3. Residual Image Ghosting

Problem:
Residual image ghosting happens when a faint image from a previously pressed design appears on a new, blank transfer. The repeated image does not belong to the current artwork and often comes as a surprise to operators during otherwise correct production runs.

Causes:
This happens due to sublimation dye residue left on the heat press platen, protective sheets, or nearby surfaces. When reheated, trapped dye gases re-sublimate and unintentionally transfer onto the new blank, even when fresh transfer paper is used.

Solution: 
To resolve this, you can use fresh butcher paper for every press, clean platens regularly, isolate printed transfers from blanks, and avoid reusing Teflon sheets. Maintaining strict press-area hygiene and correct heat settings prevents dye reactivation and eliminates repeat-image contamination.

Another alternative approach is to use silicone-treated sheets but they are not reusable, so you will have to discard it after every use. So, whether its teflon or butcher or silicon sheets, the choice depends on your particular use case.

4. Banding

Problem:

This is another one of the very common sublimation printing problems and is seen across various industries and use cases. It generally happens in all the digital inkjet printing systems and look like lines of missing ink on the printout.

Causes: 

It generally happens due to clogged print nozzles and streaks of missing ink on the printout. Another reason can be dried out inks inside the print heads. Type of paper can also cause this to happen as the printer setting might not be aligned to match the paper texture.

Solution:

You can prevent Banding simply by maintenance. Banding issues generally occur if you are not regularly using the printers. If you print regularly, you are unlikely to face them. The best way to deal with this is to prevent the ink from running out dry.

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You can use the head cleaning function of the printres to prevent the ink from running dry. Some printers need to do this manually, while in others, this function is automatic. Lastly, make sure you have plenty of ink in your machine.

5. Blurry Images

Problem: 

Image blurring in sublimation printing happens when your final print looks fuzzy, smudged, or lacks sharpness. Instead of crisp lines and clear details, the design appears soft or out of focus. Now unlike other sublimation printing problems, this one can be due to printer or the image. 

Cause: 

Many factors affect this actually, things like movement during the pressing that spreads the ink, too much heat or long press times. In some cases it can also happen if you use low quality images for printing which makes the final print look blurry. 

Solution: 

Some of the small adjustments that you can do is use heat resistant tapes, test the temperature first and then use correct temperature for the specific substrate. One thing that you can do is set a conditional image requirement, like adding only high-resolution images (300 DPI or higher).

6. Small Dots in the Transfer

Problem:

Small dots can occur on the output or the finished product due to the presence of excess moisture. These dots appear as tiny specks, spots, or pinholes scattered across the final print and ruin the otherwise perfect design. Making the whole job pointless.

Causes:

Things like dust or debris on transfer paper or a heat press can be the reason for these small dots, or, in some cases, it can happen due to clogged or dirty print heads that may spit excess ink randomly. Another thing that can lead to this is using low-quality sublimation paper or a contaminated substrate.  

Solution: 

Maintaining a clean workspace, especially around the heat press and substrates, would be significantly beneficial. You should regularly check and run a regular cleaning cycle to prevent ink buildup. Maintain clean, hygienic operational practices, such as using gloves when using substrates or a lint roller for fabrics.

How To Mitigate Sublimation Printing Problems? Key Preventive Measures

How PrintXpand Can Help

Sublimation printing comes with its own set of challenges, but a good sublimation printing solution provider is what you need to resolve all this. And PrintXpand offers all the required tools that you might need to get your sublimation printing business started.

• Streamlined Design Process: Our Product Designer Tool simplifies the design phase, allowing your customers to effortlessly create personalized products with various features, from custom shapes to social media image integration.
• Real-Time Pricing: Say goodbye to pricing headaches. PrintXpand’s live pricing feature provides instant cost calculations, ensuring your customers have full transparency and control over their expenses.
• 3D Visualizations: Boost customer confidence with the 3D preview feature. Your customers can see exactly how their mug designs will look before they make a purchase, reducing the risk of disappointment.
• Comprehensive Image Editing: The tool offers a robust suite of image editing options and effects, empowering your customers to fine-tune their designs to perfection.
• Mobile Accessibility: Extend your reach with PrintXpand’s mobile app, allowing customers to design their mugs on the go. Convenience translates to increased sales and customer satisfaction.
• Vector Output with CMYK: Deliver professional-quality mugs with vector output in CMYK color mode. Your mugs will consistently meet high standards.
• Layer Management: With layer management, designs are kept organized and editable. Your customers can make changes easily, enhancing their overall experience.
• Custom Templates: Custom templates speed up the design process, providing customers with a starting point for their creativity.
• Custom Output: The final product is paramount. Our tool guarantees that your customized mugs meet your specifications and quality standards.

Thus, by incorporating PrintXpand into your sublimation printing business workflow, you’re not just solving problems but optimizing your entire operation.

Wrapping Up

So, this was all about sublimation problems, common issues, and how to avoid them. The sublimation printing process is a tricky one as it requires accuracy and has a lot of things to take care of. But these issues are nothing to be worried about, with a little changes here and there along with reliable print design tool, your infrastructure is ready to scale. 

Want to know how PrintXpand can actually benefit your print workflow? Check out PrintXpand in action yourself. Connect with our expert to get started

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