DTF Printer Vs. Sublimation Printer

If you have been creating custom designs for mugs, t-shirts, and other fabrics, then you know that sublimation printing and DTF printing have gained popularity over the last decade. This is because they both have great print quality and produce durable results. However, sometimes, choosing between DTF and sublimation is not as easy as it sounds. I will help make the decision easier by explaining how DTF printing and Sublimation printing work, their main differences and similarities, and the kind of products they are best used for.

Right off the bat, the greatest difference between the two printing processes is the process itself. While sublimation printing uses heat to vaporize the ink and bond with the fabric, DTF printing uses heat to activate the adhesive powder and bind it with the design and ultimately with the fabric.

Other than this main difference, other characteristics stand out in comparison.

Sublimation prints have sharp and crisp colors, although the brightness is dependent on the amount of polyester in the substrate.

For example, printing on a grey fabric would result in dull colors. I recommend using bright-colored or white substrates for this process. Sublimation printing is also great for printing edge-to-edge designs because it is breathable and does not add any extra weight to the fabric.

The DTF prints have a photorealistic image because of the detailing and transfer process. A white layer is used at the bottom of the transfer paper to brighten the designs. Since RIP software is used, it is easy to regulate the color gradient with precision, resulting in high-quality prints. I wouldn’t recommend DTF printing over a wide area as it would make the fabric feel stiff and unbreathable.

However, the prints are elastic and smooth, and last long, persevering many washes without losing their color vibrancy.

DTF printing is not tied to a specific substrate. You can print on almost all the fabrics in the market: nylon, non-woven, knitting, and textiles. It is the best printer for t-shirt designs. On the other hand, sublimation printing is limited to polyester blends, polyester, and polymer-based substrates. The more polyester the fabric has, the brighter the sublimation prints will be. This aspect limits the types of substrates that can be designed using the sublimation process.

But, even with the substrate limit, sublimation can be used to print designs on polymer-coated substrates such as metal, ceramics, wood, and leather. Sublimation printing is your best option for printing on materials other than fabrics.

When you touch the DTF designs, you will feel the printing patterns made by the layer of white ink at the back of the transfer film. Although it is not a disturbing texture, it makes the design more prone to peeling and cracking, and uncomfortable to wear due to its stiffness. The original inflexibility eventually wears out after a few washes.

With sublimation printing, since the ink bonds directly with the material, no extra layer is formed. It feels as if the design and fabric are merged into one. This prolongs the design’s durability since it is less prone to cracking and peeling.

If you have a business for print-on-demand projects with some level of flexibility and convenience, either of the two options will work for you. You can print one item at a time or handle bulk orders without a problem with either DTF or sublimation printing.

The main difference is the print size. For DTF, the platen is 12” X 15” while for sublimation it is 16” X 20”, which is much bigger. This makes it easier and faster to use a sublimation printer for larger designs.

Direct-to-film (DTF) printing is a relatively new digital printing method. It uses a specialized printer to print designs directly on a special (PET) film which is then transferred to the substrate using heat. You will also need water-based inks and a special adhesive powder for the process.

DTF printing is a vast and economical way to produce high-quality and detailed prints for your business or personal use. Many people however prefer to use it to print in small batches.

You don’t need to go overboard with your budget to get a DTF printer. It is possible to convert a compatible standard printer to DTF at a relatively lower amount than buying one.

To learn more about DTF printing, check out this informative guide: What is DTF Printing? 

To compare DTF printing with another printing method, you need to understand how it works. The printing process is fairly quick and can be completed in 4 simple steps.

You need a digital design on specialized RIP software. Don’t be afraid to get intricate with the designs because DTF printing is very detailed.

In this process, the printing order is important: the colors are printed first, followed by a white base layer, to increase the brightness of the design, and also for better adhesion.

You then use a DTF printer to print the design on a PET film (Polyethylene Terephthalate). Note that the printer uses specialized pigment inks that might be more viscous compared to regular inks. Using such inks on a regular printer easily clogs the nozzles.

You should always do this when the ink on the film is still wet, otherwise, it won't work. Apply the heat-activated adhesive powder on the film and shake it around for an even layer before brushing off the excess.

This process bonds the adhesive powder with the ink and it is ready for transfer. To cure, place the film in an oven or a heat press (under hovering mode). You know it is fully cured when it forms a sticky gluey layer.

Place the design on the fabric facing down and use a heat press to transfer it. Depending on the material and manufacturer, there are different heat, pressure, and pressing time recommendations.

The heat activates the adhesive, sticking it to the material.

Depending on the type of film you used, you can do a cold or warm peel once the design is fully set. You don’t have to cure the design after peeling, so it is immediately ready.

DTF prints are high quality, durable, and resistant to peeling and fading for more washes than other printing methods. They have detailed bright and vibrant colors, and gradients with precision, making them high quality.

DTF printing is also compatible with various fabrics including polyester, cotton, silk, and blends. Since you can print on different fabrics using a DTF printer, you can decorate a variety of products such as tote bags, and caps. It also comes in handy for hard-to-print items that might be hard to print using regular printers such as shoes.

You also don't need any pretreatment for DTF printing, hence you will be saving a lot on preparation costs. Since the process is more streamlined, it becomes time-efficient which is an important aspect, especially for businesses.

With DTF printing, you only need a little initial investment on the printers which can be when converting your regular printer to a DTF printer. Afterwards, the consumables such as adhesive powder, and PET films are affordable, making them relatively cheap to get and maintain.

DTF printing is good for small customized prints because of the fast setup and execution process. However, it can be used for both large-scale and small-scale production and hence can be used for both personal and business projects.

Because the DTF transfer film sheets are cut to size, there is less waste material, making it eco-friendly.

One of the biggest cons of DTF printing is the overall high costs involved. DTF printers are relatively expensive compared to regular printers. The specialized equipment and materials needed can also be costly, especially if you get high-quality ones.

The adhesive powder and PET film wastes make DTF printing one of the least are less environmentally friendly eco-friendly printing methods. The adhesive layers also lack biodegradability and negatively impact the environment if not handled correctly.

To prevent clogging the DTF printer, you need to regularly clean it, paying keen attention to the printheads due to the thickness of the pigmented inks, which is not fun to do so often.

There is also an initial learning curve for beginners on how to handle the adhesive powders, heat press settings, and how to align the fabrics when printing.

DTF printing is an excellent option for on-demand fulfillment and small-scale printing. Its ability to create detailed and intricate designs in the boutique industry makes it a go-to for promotional products such as t-shirts, hoodies, and caps. DTF printing, because of the flexibility in its technology, is also a good option for DIY projects to make designs for personal use or gifts.

Sublimation printing has been a common practice in the textile industry for a while now. The design is embedded on the substrate using heat and sublimation inks. Due to the ink’s ability to bond with the substrate at a molecular level, the prints have sharp details and vivid colors and are durable.

However, this is also a limiting factor as sublimation inks can only bond with polyester or polymer-coated substrates. It is important to note that it does not work with 100% cotton fabrics.

Compared to DTF printing, sublimation printing is a more chemical and complex process.

The chemical process behind this printing option is what makes it possible to produce high-quality and long-lasting prints.

Create a design on your preferred software and mirror it. In this case, you don’t need the RIP software. Designs can only be printed using a sublimation printer because regular printers can’t handle sublimation inks. Some people use inkjet printers for this process, but I wouldn’t recommend it; it clogs nozzles and results in other mechanical problems.

The printer prints the design using sublimation ink on a special transfer paper.

Place the paper on the fabric facing down and put it between the heat press plates. The heat press settings for sublimation transfer are sensitive, so be sure to refer to the manufacturer’s recommendations. The heat from the heat press is set to sublime the ink from the transfer paper. 

Once it cools down, the sublimation process reverses and the ink settles and bonds with the fabric in the pattern of the design.

Once the transfer process is complete, peel off the transfer paper and enjoy your vibrant design.

Most people prefer sublimation printing over other printing methods, and that is with good reason. It has high-quality results, especially for intricate designs with rich colors. The smooth finish and fine gradients contribute to the professional finish. The prints are also durable and remain vibrant even after a few washes. This is because the ink fuses with the fabric, making it resistant to peeling, or cracking.

Sublimation printing does well with many substrates such as ceramics, glass, metal, and plastics with a polymer coating so you are not limited to just fabric. It is also easier to do all-over printing with sublimation without any color limitations. If you do it right, you can make edge-to-edge prints with photorealistic designs.

All sublimation prints are ready to use immediately after pressing without the need for curing or drying. And since sublimation uses water-based dyes that fully absorb into the substrate, it minimizes leftover waste which is eco-friendly in the long run.

Although sublimation can be done on several substrates, as a rule of thumb, they should be treated to polyester, or polymer coatings, to provide a surface that is compatible with the sublimation ink. This greatly reduces the options and is the main disadvantage of using this method to print. Items such as coated mugs are also difficult to recycle because of the mixed materials.

Sublimation printers don't use white ink, which means that the outcome of the design’s color gradient is dependent on the substrate’s background. This makes it only preferable on white or light-colored substrates. Once the design is set on a substrate, it is hard to be repurposed. Mistakes and errors translate to a loss of material and time, and a slight movement of the substrate during the transfer leads to ghosting.

Sublimation printing is relatively more expensive compared to traditional printing. The sublimation inks and coated substrates come as additional costs compared to other printing methods removing it from your top choices if your budget is low.

Sublimation printing is mostly used on all-over print designs on garments. Even though it works okay with printing on fabrics, it is also mostly used in designing promotional products such as mugs, phone covers, keychains, and water bottles. 

Due to its ability to create professional designs that meet the demand for bulk products, large-scale businesses opt for sublimation printing. They enjoy lower costs per unit making it cheaper to even customize at a scale.

Since the DTF printing business works on a wide range of fabrics compared to sublimation printing, is cost-effective with small batch production, and has a relatively low production, the ROI can be achieved in less than a year, however, this depends on other factors such as the production volume.

With sublimation printing businesses, the ROI can be achieved in under two years depending on the scale of production, and selling to high-margin markets. Some factors contributing to this are the low operating costs, and the ability to print on different materials and niche items.

To help make up your mind when starting a printing business, focus on your needs, the initial investment, your skill level, and the printing scale.

Since you can use DTF printing on a variety of materials, it makes it highly adaptable, and ideal for businesses to explore a variety of products. Since the quality of the prints remains consistent even for large prints, the business is scalable and there is always room for growth.

Sublimation printing is a good option for businesses that target niche markets such as making keychains, or phone cases. Businesses focusing on products beyond the textile industry are highly adaptable to this type of printing.