With constant advancements in large format print technology it can be difficult to keep up with what the best options are. Over the course of our 26-year history we have seen technologies come and go and had almost all of them under our roof at one time or another so we are well placed to advise on the best options for you!
Dye sublimation and UV print are two of the most common forms of large format printing and their uses often overlap. This naturally raises the question – which is best for me? Hopefully this article will answer that question.
It is mainly soft signage that can be produced with both technologies and therefore this article will focus on this area. Soft signage is the term used to refer to textile graphics such as tension fabric systems (TFS graphics), typically produced with silicone edging for fitting to a frame (SEG graphics) and commonly used for exhibitions graphics to create seamless wall displays. Other uses include flags, printed tableclothes, banners, lightboxes and backlit graphics.
UV Print:
UV printers use ultraviolet (UV) light to cure inks instantly as they are applied to the surface of a wide variety of media types including PVC banners, fabrics, vinyls and paper to name a few. Modern UV printers use LED UV lamps which don’t generate much heat meaning heat sensitive materials can be printed without risking damage to the print surface, widening the range of materials that can be printed. UV print is also incredibly scratch resistant, can stand up to external weather conditions and is capable of producing very high-quality graphics.
However, one of the drawbacks to UV print is that the ink surface is at risk of ‘cracking’ if folded, this is more of an issue when soft signage materials are being used. This often means that large fabric prints can’t be packed down into small packages and sent out without risking damage to the print finish. This can make shipping and long term storage for reuse in the future a problem and is one of the key areas that dye sublimation wins a point over UV.
3.2m Fabric Graphics on UV Printer
Dye Sublimation Print:
Dye sublimation differs to UV print in a number of ways. Firstly, the water based dyes used during the print process are not cured instantly by UV light, they are air dried with heat and fans and then a separate heat process is used to ‘sublimate’ the print. This second step in the process is where the printed media is passed through a heat calendar which subjects the graphics to specific heat, pressure and exposure time dependent on the type of material being used. This heat process operates at roughly 200 degrees Celsius and causes a chemical reaction during which the dye is turned into a gas which then permeates into and bonds with the fibres of the fabric.
Dye sublimation graphics during the calendaring process
This process is what gives dye sublimation print its durability, resistance to fading and makes it perfect for soft signage because the print doesn’t just sit on the surface of the material like UV print but rather is dyed into the fibres of the material leaving a perfectly smooth finish.
Dye sublimation is perfect for soft signage applications like seamless fabric walls for exhibition graphics, tablecloths, flags and stretch fabric displays to name a few, thanks to its flexibility and durable nature. Most dye sub printed graphics can also be machine washed which is a major advantage over UV prints as prints can be reused time and time again. The durability and longevity of dye sublimation graphics is one of the key sustainability factors for this technology. The ability to reuse graphics and avoid the need for reprints reduces the amount of material being used and in turn the carbon footprint attached to the graphics.
However, its not all sunshine and rainbows, there a couple of drawbacks to large format dye sublimation print. One of which is that the process is primarily suited for polyester based fabrics. This means it cannot be used on your traditional banner materials, vinyls, etc. UV print benefits from being suitable for a much wider range of materials.
Secondly, dye sublimation is a two step process as opposed to UV print which is cured instantly and can be handled and finished straight away. The extra step of sublimating graphics adds time and an additional complexity to the process.
3.2m Dye Sublimation Printer
Which is best for your project?
When deciding which process is best for your project we would look at factors such as lead time, budget, project requirements and desired outcomes. Besides from a couple of applications that are unique to dye sublimation there really isn’t a right or wrong answer on which print process to use.
If your project is needed extremely urgently (which is very common in the exhibition graphics and events industry), will only be used once before being recycled and isn’t suited to a fabric media then UV print is the obvious winner. However, textile graphics that have a lot of very small text (such as terms and conditions hidden in a corner) may also be better suited to UV print as the instant drying prevents any ink bleed and allows for sharper text at very small sizes.
For the majority of textile applications and fabric prints, dye sublimation will be a more cost effective, longer lasting and more practical solution with the added benefit of being reusable in the future! The incredible colour vibrancy that is achievable with dye sublimation is also noticeably better than that of UV print which is particularly beneficial for things like backlit graphics. Textiles with high levels of stretch and graphics that require significant ‘show through’ such as flags will be done with dye sublimation as UV just isn’t suitable for these applications.