It is the era of modernization. People know the best way of saving time and money while still giving value to their choice, maintaining quality in their clothes and their styling. In short, here comes the role of sublimated patches in their life. These patches are just perfect for the people of the modern era as they are durable, affordable, light in weight, and anyone can design their own patches according to their own choice.
These patches give a high-quality and premium look to the apparel on which they are applied. These are also best for people who love to wear clothes of their own design. This idea of custom patches has fascinated the whole world, which has resulted in a rapid increase in its demand in the last few years. According to an estimate, until 2033, the USD 3.14 billion-worth market of patches can increase to USD 4.61 billion.
The most in-demand technique of today’s time for printing patches is a printing method that involves the sublimation process. This technique was first introduced by Noël de Plasse, a Frenchman working in Lainière de Roubaix, a textile company. At the time of its creation in 1957, it was frequently used for printing clothes, apparel, and various fabrics, but its usage expanded over time.
What Is Sublimation?
The inventions of modern times have a deep history rooted in the observation of natural phenomena. The invention of sublimated patches is linked with one such phenomenon known as sublimation in science. This phenomenon involves the direct transformation of a solid substance into a gas without converting into a liquid state.
A common example can be observed with ice cubes, where solid ice converts directly into gas under certain conditions.
The Sublimated Patch Printing Technique
In this technique, under high temperature and pressure (about 350–450℉), the sublimation of hard dye takes place, converting it into a gas. This gas then penetrates and deposits into the base patch material, which contains polyester. The presence of polyester enhances the material’s ability to absorb dyes.
For proper dye penetration, it is necessary to use a base material in which polyester makes up less than 65% of the total material. This creates a strong bond between the base material and the dye. Patches produced using this method are strong, resilient, and contain fine, detailed prints. Careful monitoring and precise temperature control are required to achieve optimal results.
The dyes used in this process are special sublimation inks, commonly known as water-insoluble disperse dyes. Polyester enhances dye absorption due to its resistance to water and its regularly arranged molecular structure. These dyes consist of tiny particles that easily sublimate and bond with polyester fibers.
Sequential Flow of the Patch Sublimation Process
Selection or Creation of Artwork for Printing
Using suitable design software, artwork is created for printing on patches. Dispersed dye ink is then used to print the digitally designed artwork onto specialized sublimation paper, initiating the process.
Base Material Pre-Treatment
A flawless and strong bond between the base material and the dye ink can only be achieved in the absence of dirt or impurities. Therefore, the base material must be thoroughly cleaned before applying the print.
Sublimation Heat-Pressing
The base material is pressed at a temperature of approximately 190°C to 210°C. The printed paper is placed on the base material and subjected to high pressure for about one minute. During this process, the solid dye particles sublimate into gas and bond with the base material.
End Product
After the pressing process is complete, the paper is removed to reveal an elegant, resilient, and finely detailed printed patch with high color permanence.