DTF vs Sublimation: Which Printing Option is Better?

If you are looking for a printing technique that can yield impressive results, then DTF and Sublimation will be the top two contenders. Both of these two printing methods can deliver high-quality prints with great details and vibrant colors. Moreover, both of them are also categorized under the heat transfer printing section. However, they feature some distinctive differences that make each suitable for different purposes.

To better understand the differences and how each printing method should be employed, Merchize will guide you through a detailed comparison between these two printing technologies.

What is DTF (Direct-to-Film) Printing?

Direct-to-film printing is one of the latest inventions in the printing industry. The introduction of DTF has helped to remove many limitations in printing. For example, DTF can print on various materials, from synthetic to natural fiber fabrics. It can also handle complex designs with intricate details and vibrant colors.

Technically, DTF could be considered a form of heat transfer printing. It doesn’t require direct printing onto the materials. Instead, the design will be printed onto a PET film and then transferred to the substrate using a heat press machine.

DTF’s impressive ability is a result of smaller technical improvements here and there.

• Pigment-based inks: DTF utilizes specialized pigment-based inks that offer high color vibrancy and durability. These inks are designed to adhere well to the film and subsequently to the fabric, ensuring long-lasting prints with rich colors.
• DTF printers: DTF uses dedicated printers that can achieve high-resolution prints with fine details, which is often challenging for other transfer methods.
• PET Film: DTF uses high-quality PET (polyethylene terephthalate) film. This type of transfer film is heat-resistant, and smooth on the surface, which ensures consistent printing without wrapping or distortion as well as excellent ink deposition. Especially, PET film is compatible with a wide range of fabrics, including cotton, polyester, blends, and synthetic materials.
• Adhesive Powder: DTF employs a heat-activated adhesive powder as a bonding agent. This powder is applied to printed film. During the heat press process, it melts under high temperatures, creating a strong bond between the ink and the fabric. This results in prints that are more durable and resistant to washing and stretching.

DTF Printing process:

Now, let’s dig into the detailed process of how DTF prints are made:

1. Create a design using graphic design software.
2. Print the design onto a PET film using a DTF printer equipped with DTF inks.
3. Apply a hot melt powder to the printed film while the ink is still wet.
4. Cure the film using a heat press or an oven to bond the powder to the ink.
5. Place the cured film onto the fabric and use a heat press to transfer the design. The heat activates the adhesive, bonding the design to the fabric.
6. After cooling, peel the film away, leaving the design on the fabric.

Advantages of DTF:

• Versatility: DTF works on a wide variety of fabrics, including cotton, polyester, blends, silk, nylon, and more. Additionally, it’s also suitable for printing on non-textile materials like leather, wood, and other surfaces.
• High-quality prints: DTF can produce vibrant, high-resolution prints with excellent color fidelity, be it gradient or photographic designs. The use of white ink allows for bright and opaque prints on dark fabrics.
• Durability: DTF prints are durable and can withstand repeated washing without significant fading, cracking, or peeling. The adhesive powder used in the process ensures strong adhesion to the fabric.

Disadvantages of DTF:

• Slight texture: DTF prints can have a slightly raised print texture due to the additional adhesive layer. While the print is generally soft and flexible, it may not be as smooth as sublimation prints or DTG prints on cotton.
• High equipment costs: While the setup costs are lower than screen printing, DTF still requires investment in specialized printers, heat presses, and adhesive powder application equipment.

What is Sublimation Printing?

Similar to other heat transfer printing techniques, sublimation also uses the same mechanism to create print: Print is transferred from transfer paper onto the substrate and bonds with the material under high temperature and pressure.

While the process is the same, sublimation holds a secret that allows it to achieve some impressive printing outcomes. It’s the special dye-based inks that can convert from a solid state directly to a gas without passing through a liquid state, which is also why it is called sublimation. This ink is the special factor that forge the magic of sublimation: It allows the ink to penetrate the substance’s fiber and become a part of the material.

Sublimation Printing Process:

To better understand how sublimation works, let’s go through all the steps of the sublimation process:

1. Create a design using graphic design software.
2. Print the design onto sublimation transfer paper using a sublimation printer and sublimation inks.
3. Place the printed transfer paper onto the polyester substrate and use a heat press. The heat causes the ink to sublimate and bond with the polyester fibers.
4. Remove the transfer paper, revealing the design permanently embedded into the substrate.

Advantages of Sublimation

• Vibrant, bold, high-quality prints: Sublimation printing can produce highly detailed images with bright, vibrant colors due to the high quality of dye-based inks used in the process. Custom-designed photo gifts, like mugs or phone cases, showcase intricate designs and vivid hues that capture the original artwork or photograph perfectly.
• Durable and seamless prints: With sublimation printing, the ink will penetrate and integrate with the material, leaving no trait of print layers. Instead, prints and fabrics become just as one.
• All-over print design: Sublimation printing is ideal for all-over prints, as the fabric retains its original texture and flexibility, even when the entire surface is printed.
• Suitable for a wide product range: Sublimation printing is suitable for a wide range of products, including apparel, home decor, and promotional items. You can use sublimation printing to print on textiles as well as other materials like metal, plastics, ceramic, and more.

Disadvantages of Sublimation

• Only compatible with light-colored polyester fabric: Sublimation printing is only effective on light-colored, polyester-based fabrics, as the dye needs to bond with synthetic fibers. Attempting to sublimate on dark cotton t-shirts results in poor color reproduction and a design that quickly fades or washes away.
• Require expensive investment: Setting up a sublimation printing operation requires significant investment in specialized equipment, including sublimation printers and heat presses.

Similarities between DTF vs Sublimation

Both DTF and sublimation rely on the power of heat and pressure to transfer printed designs onto the substrate. That’s why whether you are applying sublimation or DTF, you always need a heat press machine at hand.

Compared to other printing methods, DTF and sublimation share one advantage: Both can deliver great-quality printing with a high level of precision. Both printing methods can bring the vibrancy and complexity of a design to life, creating captivating and impressive prints on fabrics.

Another plus point for these two printing techniques is that both can portray a full range of colors with precision. It is perfect for showcasing photographic designs and special graphic effects like gradients. This opens a whole world of possibilities for printing.

DTF and Sublimation printing are also two popular printing choices for making customized and personalized orders. Since both don’t require a complicated setup, it is easy to switch designs. You can also these two options are also quite popular among print on demand businesses, especially for sublimation printing.

Differences between DTF vs Sublimation

Materials

DTF has the upper hand compared to sublimation when it comes to versatility. This advanced printing technique is compatible with a wide range of materials, including cotton, polyester, nylon, blends, and more. And the printing quality is consistent across different materials.

On the other hand, sublimation is exclusively available for polyester or polyester-coated fabrics only. If you use sublimation printing on natural fiber fabrics like cotton, the print won’t be able to penetrate into the fiber, causing it to fall out or peel off easily.

In addition, sublimation ink would only pop on white or light-colored materials. But for DTF, prints can shine no matter what materials it sit on.

If you prioritize versatility and prefer working with all types of materials, then DTF is a more fitting option for you.

Durability

When it comes to durability, sublimation can beat almost any printing method to date including DTF. The working mechanism of transforming ink into gas form and then solid form again allows the ink to penetrate the fiber deeply.

Rather than sitting on the surface, sublimation dye soaks up into the fabric and becomes one with the materials. This deep integration creates incredibly resilient prints that won’t wash off or fade away no matter how many washes they went through.

Texture and hand feel

As mentioned above, sublimation creates prints that seamlessly blend with the materials. You can feel the original soft texture of the fabric and nothing of the prints. DTF prints, on the other hand, have a slightly raised texture that can thicken the material.

All-over print compatibility

Since the dye embeds into the fibers, the fabric retains its original texture and flexibility. This is particularly important for all-over prints, as it ensures the garment remains comfortable and retains its natural feel. Plus, sublimation printers can handle large rolls of fabric, allowing for continuous, uninterrupted prints. This makes it possible to create designs that cover the entire surface of garments like t-shirts, leggings, and even large items like bed sheets and curtains.

On the contrary, DTF prints usually have a slightly noticeable texture on the fabric. The adhesive layer might also affect the fabric’s flexibility, especially on larger surfaces. For this reason, it is not suitable for all-over prints. Unlike sublimation, DTF printing typically uses PET films for transferring designs. These films come in standard sizes, which can limit the size of the design.

Which one to choose?

Both sublimation and DTF are suitable for print on demand businesses as they can allow flexibility for customization and personalization with no limitation in terms of minimum quantity. For example, at Merchize, we currently apply sublimation printing on a wide variety of products, from apparel to other decoration products.

However, in some cases, one printing method will be more suitable than the other.

When to choose DTF?

DTF is a great choice for small and medium-sized businesses. It has the versatility that allows you to experience different types of materials and products, allowing you to venture into many spaces in the market. Plus, the initial investment cost is manageable and suitable for small to medium-sized businesses. The running costs for this printing method are also inexpensive, so you won’t have to put out a significant investment.

When to choose Sublimation?

Sublimation runs on a larger scale. It takes up a bigger space for printing machines. The investment is also much higher. All of which makes it only suitable for established businesses, and not for smaller, newer ones.

In addition, sublimation works very well on synthetic fibers like polyesters and nylons which are commonly used in sportswear. It is a no-brainer choice to choose sublimation printing for sports apparel.

Conclusion

Both DTF and sublimation printing offer unique advantages, making them invaluable tools for different printing needs. Whether you’re just starting out or looking to expand your printing capabilities, understanding these methods will help you make the best choice for your business. Don’t be afraid to explore both techniques and find the one that fits your needs perfectly. With the right approach, you can create stunning, high-quality prints that will impress your customers and set your business apart.