Direct-to-vinyl (DTV) printing has become a popular method for creating custom designs on vinyl materials. Unlike sublimation printing, which uses a dye-based ink that infuses into the substrate, DTV printing uses a solvent-based ink that sits on top of the vinyl. This leads many people to wonder – can you use a sublimation printer for DTV printing? The short answer is no, sublimation and DTV printers are inherently different technologies that are not interchangeable. In this article, we’ll look at the key differences between sublimation and DTV printing and why you can’t use a sublimation printer for DTV applications.
How Sublimation Printing Works
First, let’s look at how sublimation printing works. Sublimation uses a specialized dye-based ink that turns into a gas when heated. The process works like this:
- The image is printed onto special sublimation paper using a sublimation printer loaded with sublimation ink.
- The paper is then laid on top of the substrate, usually a polyester fabric or coating.
- Heat and pressure are applied, which causes the dyes to turn into a gas that permanently bond with the substrate.
- The result is continuous tone printing that becomes part of the substrate for a permanent print.
The keys to sublimation printing are the sublimation ink and polymer-coated substrates. The process depends on the ink temporarily becoming a gas to infuse color into the polymer coating. Normal pigment-based inks will not work for sublimation.
How DTV Printing Works
DTV printing uses a very different process from sublimation:
- The design is printed directly onto vinyl using a specialized DTV solvent ink printer.
- The ink cures and bonds to the surface of the vinyl rather than infusing into it.
- The result is a printed design sitting on top of the vinyl material.
There are a few key differences that make DTV printing distinct from sublimation:
- DTV ink is a specialized solvent-based ink that bonds to the vinyl surface.
- There is no need for special substrates – the ink adheres directly to standard vinyl.
- The ink cures rather than turning into a gas, so it sits on the vinyl instead of infusing.
Why Sublimation Printers Can’t Be Used for DTV
With an understanding of how the two processes work, we can now look at why sublimation printers can’t be used for DTV printing purposes.
Ink Compatibility
The biggest obstacle is ink type. Sublimation printers use a specialized dye-based ink that is formulated to infuse into polymer coatings. DTV printers use an entirely different solvent-based ink that adheres to vinyl surfaces.
Sublimation ink will not properly bond to vinyl. The dyes will not create a proper cured print sitting on top of the material. Instead, the ink will transfer, bleed or wash off. Using sublimation ink on vinyl will result in very poor print quality.
Print Process
Beyond the ink, the printing process itself is incompatible. Sublimation requires high heat and pressure to vaporize the ink so it can infuse into the substrate. DTV printing relies on the ink curing and bonding to the material surface.
Applying heat and pressure during DTV printing will not improve dye sublimation. In fact, it can distort the vinyl and still result in poor ink adhesion.
Print Resolution
There is also a difference in print resolution. DTV printers need to produce high quality prints with resolutions around 1440 dpi or higher. Sublimation printers typically print around 300-400 dpi.
The lower resolution of sublimation printers will result in visible print dots and overall poor image quality for DTV applications.
Alternatives to Using a Sublimation Printer for DTV
Since sublimation and DTV printers are fundamentally incompatible, what are the alternatives if you want to work with both technologies?
Purchase a Dedicated DTV Printer
The best option is to purchase a printer designed specifically for DTV printing. Popular desktop DTV printers include:
- Roland VersaStudio BN-20
- Mimaki CJV150 Series
- Mutoh ValueJet 1626UH
These printers are engineered to work with DTV inks and handle printing directly on vinyl. Image quality and printer reliability will be far superior to attempting to modify a sublimation printer.
Use a Print Provider for DTV
If purchasing a DTV printer isn’t feasible, you can use a print provider that offers DTV printing services. Send them your design files and have them produce the DTV prints for you. This is a good option if you only occasionally need DTV prints.
Coat Substrates with DTV Receptive Coating
Some suppliers offer vinyl materials and hard substrates that are coated with a layer formulated to work with DTV inks. This allows you to print DTV designs on substrates optimized for use with solvent inks.
The DTV receptive coating means the solvent ink will bond properly. Just be sure to find a substrate coated specifically for DTV ink compatibility.
Summary
In summary, sublimation and DTV printing are two very different technologies that are not interchangeable. Dye sublimation ink will not work properly with vinyl, while DTV solvent ink is incompatible with sublimation printing. To achieve quality DTV prints, you need to use:
- A dedicated DTV printer
- A print service provider
- DTV receptive coated substrates
With some creativity, you can find solutions that allow you to incorporate both sublimation and DTV printing into your production process. But you should not attempt to use a sublimation printer directly for DTV printing purposes. The two technologies have fundamentally different ink and printing requirements that prevent simple interchanging between them.
| Sublimation Printing | DTV Printing |
|---|---|
| Dye-based ink infuses into the substrate | Solvent-based ink sits on top of the substrate |
| Requires polymer-coated substrates | Works directly on vinyl |
| Lower resolution around 300-400 dpi | Higher resolution around 1440 dpi or higher |
| Requires heat and pressure | Ink cures and bonds without heat/pressure |
The Bottom Line
Sublimation and DTV utilize very different printing technology. Although creative solutions exist to produce both print types, you cannot directly substitute a sublimation printer for DTV printing purposes. To achieve quality DTV results, you need to use equipment and substrates designed specifically for solvent DTV inks.