So, again, why sublimation? Three answers really: quality, quality and quality! The screen print process requires that each color be placed onto the shirt separately (the more colors, the more setup fees) so, unless you can get a screen printer to blend in 128 colors you’ll never get the photo quality of sublimation.

Since screen printing is placed on top of the shirt, the inks tend to peel and fade over time, sometimes as quick as the first washing. Have you ever noticed that raised, sticky feel when you touch a screen printed image? That’s dried ink just waiting to peel away.

So what’s so great about sublimation? Glad you asked. When a personalized shirt (for example) is made using dye sublimation the image is created on the computer using photo software such as Corel Draw. The image is then printed onto a special transfer paper using very special inks. Dye sublimation inks typically cost anywhere from 5 to 10 times more than standard ink such as that used in screen printing.

The image is then pressed onto the material using extreme heat (400 degrees) and pressure. Under heat and pressure the ink turns into a gas, allowing it to permeate the fibers of the fabric. The result is a photographic quality image that is smooth to the touch, won’t fade or peel, and will last through dozens and dozens of wash cycles. It’s been my experience that the fabric wears out before the image does.

So, screen printing or dye sublimation? If your reputation depends on quality as mine does, there’s really no question at all.

Is there ever a time when screen printing is appropriate? Yes, for promotional give-aways, and other events where the product will more than likely be worn once and never again. If, however, the product is to be a gift or something that needs to last, dye sublimation is the way to go.