Sublimation printing:
the best way to print
on almost anything.
We've worked with nearly every printing technology available. Screen printing, DTF, DTG, engraving, UV flatbed — we do it all. But if you ask anyone on our team which process we'd choose if we could only keep one, the answer is the same every time: sublimation. Here's why.
So — what actually is sublimation?
Sublimation is a printing process where ink doesn't sit on top of a surface — it becomes part of it. Using heat and pressure, specially formulated dye ink converts from a solid directly into a gas (skipping the liquid phase entirely — that's the "sublimation" part), and that gas penetrates deep into the polymer structure of the substrate. When it cools, the dye re-solidifies inside the material.
The result is a print with zero surface layer. No film. No texture you can feel with your fingernail. No edge you can peel. The image is physically inside the material — which means it behaves exactly like the material does. If the fabric stretches, the print stretches. If the ceramic goes in the dishwasher, the print survives. There's nothing to crack, fade, or flake because there's nothing sitting on the surface to begin with.
The science behind it
Sublimation inks contain dye suspended in a carrier. When pressed at 375–400°F, the dye converts to gas and the pores of the polymer substrate open under heat. The gas enters the open pores and bonds with the polymer chains at a molecular level. When pressure is released and temperature drops, the pores close — trapping the dye permanently inside the material. No adhesive. No topcoat. Just dye and polymer, bonded together.
The Print Forge take
Sublimation is, in our opinion, the finest form of printing available for the right application.
We've said it to customers, we say it to each other, and we'll say it here: when sublimation is the right tool for the job, nothing else comes close. The color accuracy, the durability, the way a properly sublimated piece just looks and feels different from everything else — it's why this process is at the center of everything we do at Print Forge Designs. Our entire coating line was built around it. When you hold a finished sublimation piece from our shop, you'll understand immediately why we feel that way.
The process, step by step.
Sublimation looks simple from the outside — print, press, done. But what's actually happening at each stage matters a lot, and getting it right is what separates a great result from a mediocre one.
Step 01
Artwork prep
Design is color-profiled for sublimation output — RGB color mode, high resolution (300 DPI minimum), printed in mirror image onto transfer paper.
Step 02
Sublimation print
The mirrored design is printed onto transfer paper using sublimation inks on professional-grade printers. This is not the final product — it's the transfer vehicle.
Step 03
Coat (if needed)
Non-polymer surfaces like wood, glass, or metal require a sublimation-ready coating first. We apply ours in-house — one of only two US shops that do this.
Step 04
Heat press
Transfer paper is placed face-down on the substrate and pressed at precise temperature and pressure. The ink converts to gas and bonds into the material.
Step 05
Peel & cure
Transfer paper is peeled. The design is now permanently inside the substrate. For coated pieces, parts go through our industrial ovens to fully cure the coating.
Getting the artwork right.
Sublimation rewards good artwork preparation and punishes bad preparation. Here's what matters most going into a sublimation job:
Color mode: Always design in RGB, not CMYK. Sublimation inks are calibrated for RGB output — CMYK files will shift colors in ways that can be hard to predict and harder to fix after the fact.
Resolution: 300 DPI at print size is the minimum. Sublimation can reproduce photographic detail at a level that exposes every flaw in a low-resolution file. If your artwork is blurry at 100% zoom on screen, it'll be blurry on the product.
Background: Because sublimation bonds with the substrate itself, any "white" in your design is actually transparent — the substrate color shows through. On a white substrate, that's fine. On an off-white or cream substrate, whites in your design will shift to match. Design accordingly.
Bleed: For edge-to-edge prints, always add bleed beyond the cut line. Sublimation transfer paper shifts slightly under heat — bleed compensates for that and ensures clean edges on the final product.
"When the artwork is right, a sublimation print looks like the image was born inside the material. That's not an exaggeration — it's just what the process does."
Where sublimation truly shines.
Sublimation is not a one-size-fits-all solution — but where it works, it works better than anything else. These are the applications where sublimation is the clear best choice:
All-over apparel
Edge-to-edge, seam-to-seam coverage on polyester. No other method matches it for full-coverage garment printing.
Photo reproduction
Photographic detail, smooth gradients, and accurate skin tones on tiles, panels, and portraits.
Ceramic & hard goods
Dishwasher-safe, UV-stable prints on tiles, mugs, and drinkware that genuinely last.
Coated wood & custom shapes
With our proprietary coating, we can sublimate onto custom-cut wood in virtually any shape or size.
Personalized gifts
One-of-a-kind pieces where quality and longevity matter more than cost-per-unit.
Corporate & branded goods
Premium branded merchandise that looks and feels elevated — not like a heat transfer.
What you can sublimate on.
The golden rule of sublimation is this: the substrate must either be a polymer (polyester, polymer-coated) or receive a sublimation coating first. Here's a breakdown of what works and why:
Polyester apparel
100% polyester or high-poly blends. White or light colors only. Best results on bright white fabric.
Ceramic tiles
Pre-coated ceramic tiles. Exceptional color depth and photo reproduction. Dishwasher safe.
Mugs & drinkware
Polymer-coated mugs and drinkware. Wrap-around prints, dishwasher resistant.
Glass
Requires our sublimation coating. UV-stable, vivid results. Excellent for décor and signage.
Custom-cut wood
We cut and coat in-house. Any shape, any size. Ornaments, signs, frames, plaques.
Aluminum & metal
Coated aluminum panels for signage, awards, and photo prints. Extremely durable.
Family portraits & murals
Large-format sublimation on coated panels or fabric. Gallery-quality output.
Custom gifts
Phone cases, keychains, ornaments, coasters — virtually any polymer-compatible surface.
When to choose sublimation —
and when not to.
Sublimation is our favorite process, but we'll always tell you the truth: it isn't always the right tool. Here's how to know which situation you're in.
✦ Choose sublimation when...
Consider alternatives when...
If you're not sure which process is right for your project, that's exactly what we're here for. Reach out and describe what you're trying to make — we'll tell you honestly which method will get you the best result, even if it isn't sublimation.
What to expect from a sublimation print.
When sublimation is executed correctly, here's what you get:
Vivid, accurate color
Sublimation reproduces the full RGB color spectrum with exceptional accuracy and saturation.
Zero surface feel
No raised edges, no texture, no film. The print is invisible to the touch — it's part of the material.
Wash & UV resistance
Properly sublimated prints don't fade in the wash or in sunlight the way surface-applied inks do.
Photographic sharpness
Fine lines, micro-detail, and smooth gradients reproduce cleanly at any scale.
No color count limit
Full-color, unlimited colors, photorealistic images — all in one pass. No setup fees per color.
Consistent at scale
Piece 1 and piece 1,000 look identical. Digital control means zero color drift across a run.
From the Print Forge team
This is why sublimation is at the center of everything we do.
We built our entire operation around this process — industrial coating booths, curing ovens, professional sublimation printers, and an in-house coating capability that only one other US shop can match. We didn't do that by accident. We did it because we genuinely believe sublimation, when done right, produces results that no other printing method can touch. Every time a customer holds one of our finished pieces for the first time and looks at us like they can't believe what they're holding — that's sublimation doing exactly what it's supposed to do. That reaction never gets old.
