Drinkware dye-sublimation is a popular method of decorating this popular gift. Although digital printing is a somewhat new technology, companies who have invested in this technology are already reaping the benefits.
Dye-sublimation is the process of taking sublimation paper (paper with a special polyester coating) and heating it at a very high temperature so it adheres to a substrate. The substrate must be coated in polyester in order for this process to work. Once the heat is applied to this paper, the ink turns to gas and permanently bonds with the surface of the product.
Dye-sublimation first starts out on a computer. The graphic is manipulated to the artist’s liking and is then sent to a large format roll-to-roll inkjet printer to print. After the images have been printed out, the operator then cuts the images and separates them into different sku’s. Once an order comes in, the operator takes the cut-out image, places it inside, next to or around the drinkware piece where it is then taken to a heat transfer machine. The part and the paper are placed into the jig, heated for 45 seconds and then shipped to its final destination.
Dye-sublimation is a great process for smaller companies who are just starting out. It offers heat press machines for practically any size business and the consumables are not too expensive. Once a company grows, this process because much too slow and requires too many variables. Printing, cutting and heating the graphics seems like a small job when making a few personalized drinkware pieces but soon becomes cumbersome when your sales begin to grow.
Cylindrical inkjet printing also utilizes a inkjet printer to print the graphics. However, these graphics are printed directly onto the vessel eliminating sublimation paper, cutting and heat sealing. Once the graphic is created in the digital cylinder printer’s software, it is transferred directly to the machine for printing.
For POD companies, this process shortens the in-hand cycle. The artwork needs to be prepared for print only once per vessel type. Once the file is properly labeled and a corresponding label is made, the operator will pick the part, print the barcode and then deliver it to be printer. The machine operator will then place the drinkware piece in the machine, scan the barcode and print the proper graphics. Once it is printed, it is shipped off to the customer. This process can produce around 2-3 parts per minute, depending on the height of the artwork and the speed of your operator.
The benefits of such a machine are endless. Companies can completely transform their drinkware to levels they have never even imagined. Those who are starting can completely differentiate themselves from competitors. For those who are currently sublimating, you are decreasing your production times and increasing quality and margins. This process is more sustainable and greatly reduces the amount of waste in terms of paper and plastic. Aside from the production improvements, the quality is stunning and will highlight the artist even further.
Inkcups’ Helix® Digital Cylinder Printer is an advanced machine with an open software capable of connecting to production facility. This machine prints in full-color, 360-degrees on numerous vessel types such as stainless steel, powder coated metals, plastic, glass and more. Highlight crowd-sourced graphics that give meaning to drinkware. Produce a product that enhances the creativity that these artists possess.
Learn more about Inkcups’ Print on Demand Drinkware Production Workflow
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