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Breaking Down Dye Sub, Part 1

THE HEAT ON Dye Sublimation

Why it’s a hot trend Michael Syverson has been is the next big surge in the sign and in the printing industry for Din the digital textile printing industry. graphics industry almost 20 years, at the fore- Quick to take off in Europe, dye sub is front of the pivotal time of becoming the choice technique for end- and what you need analog to digital conversion. users because of the ef ciencies in fabric to know about it Syverson worked for EFI- shipping and handling, as well as the rich, VUTEk for 10 years and was instrumental high-quality results. Fabric is beautiful,

BY MICHAEL SYVERSON, in the development and rollout of ve indus- but printing on it can be challenging. DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL COMPILED BY MARILYN trial inkjet printing devices, helping to create With this issue, we are launching a DAVENPORT and re ne many techniques that were critical ve-part series that will explore the in- to successful print through digital methods. tricacies of dye sublimation with guest Marilyn Davenport is the Public Relations expert Michael Syverson, Director of director for Global Imaging Inc. Special Projects at Louisville, Colo.-based

To get into dye sublimation printing, you basically need a printer, some sort of heat press to sublimate the ink and some ﬁ nishing equipment.

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SBJUL.indd 40 6/18/12 9:47 AM PrinterEvolution. Syverson has more than 20 years in the printing industry and was an applications specialist on the VUTEk project team when it unveiled the first dye sub printer in 2001. Let’s begin There are really three types of printers: all-in-one units with a built-in fixation heat press; printers that just print either transfer or direct; or in some cases, both. with an overview of the dye sublimation process from inks to equipment, but in subsequent articles we will further exam- ine such topics as substrates, inks, heat setters, finishing, marketplace economics and workflow. Although there are many different approaches and variants to sublimated fabric printing, we will fo- cus primarily on transfer dye sublimation because that is more widely used in the U.S. grand-format arena. We asked Mike Aqueous dye sub printers, such as this Evo33 from PrinterEvolution, are in demand because the following questions: of the green benefits of using water-based inks over oil-based or solvent-based inks. Q. What is dye sublimation? A. Dye sublimation is the process of converting solid dyes into a gas without going through the liquid stage. Heat and pressure are used to infuse colorant into a polymer material (usually polyester). There are two basic methods for printing with dye sublimation inks, direct and transfer. Transfer is the most common method in the U.S. and consists of printing an image on a transfer paper and sublimating the image onto a polyester- based product, usually a textile. The direct process differs from transfer printing in that the image is printed directly on a coated fabric and then sublimated without the use of paper.

Q. What are the advantages and disadvantages of the direct and transfer processes? A. Both methods require heating the Customers in the soft signage, trade show, retail, P.O.P., event and entertainment industries fabric in order to infuse the ink into the are really enjoying the benefits of dye sublimation textile printing and a huge opportunity fabric, but both have their pros and cons. exists in these areas from small to large sign shops.

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SBJUL.indd 41 6/29/12 11:14 AM Transfer printing allows the most flexibility in terms of substrate range. You can basically sublimate to any polyester textile (or other polyester coated product for that matter). Transfer printing is very efficient, as you only need to profile and set up the printer for the one transfer paper you are using. Setting changes for the different fabrics are made at the heat press calendar. And printing on paper means you don’t have to worry about the fabric moving, stretching or wicking thereby giving you a clearer, more per- fected image with sharper color “pop.” Direct print has been around for several years and many pieces of equipment have been designed specifically for this application. An advantage of this is you can eliminate the need for transfer pa-

DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL per altogether, which can simplify the process in some ways. Direct printing also increases strike-through, making the image apparent on both sides of the fabric. In some applications this may be desirable. On the downside, you need to charac- terize the printer for each fabric (separate ink limits, profiles, etc.) Additionally, you need coated fabrics to provide the best possible output for direct print. This can add cost, sometimes mitigating the cost of transfer paper. Also, there isn’t Dye sublimation allows for a wide variety of substrates, including silk. (Photo courtesy Mimaki) as wide an array of direct-coated fabrics available as uncoated fabrics. Finally, in many cases the output from direct print is not as sharp as a transfer printed piece. The best print equipment offers both, giving you the ability to produce graphics with either the direct or transfer method depending on the client need.

Q. What are the different dye sublimation inks and coatings? A. There are three popular variants of dye sub ink: solvent-based ink, oil-based ink and water-based ink. The transfer applications for each of these ink types are roughly the same, using coated transfer paper to release the ink effectively. The main difference with these inks is the me- dium in which they are carried. Some of the reasons dye sublimation is a growing market is because of the efficiencies in fabric shipping and handling, as well as the rich, high-quality results. (Photo courtesy Fisher Water-based ink is the most common Textiles) formulation of ink for dye sublimation

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SBJUL.indd 42 6/14/12 3:45 PM Transfer printing is very efficient, as you only need to profile and set up the printer for the one transfer paper you are using.

and by far the most eco-friendly. With Q. Who uses dye sublimation and green printing growing in popularity, what are its applications? water-based ink offers outstanding at- A. Customers in the soft signage, tributes. Printers that print with water- trade show, retail, P. O. P. , event and en- based ink range from in-home consumer tertainment industries are really enjoying converted printers to grand-format in- the benefits of this type of textile printing dustrial inkjet printers. Solvent-based and a huge opportunity exists in these and oil-based units are primarily seen in areas from small to large sign shops. the grand-format space. Typical applications include banners, Historically, oil-based and solvent- stretch graphics for exhibitions, flags, based inks were used because of difficul- T-shirts, retail point of purchase, tents, ties with water-based inks, availability of even hot air balloons. Also, imprintable water-based compatible print heads and a items such as coated ceramics, wood and compatible transfer paper. As paper gets metals use this method, but it is impor- wider (10 feet or 3 meters) it can become tant to note that dye sub is designed only unstable during print, in terms of wrinkles for polyester based materials. In the case (or cockles), which can cause print arti- of solid substrates, like a coffee mug for facts or head strikes. Additionally, when example, the mug must have a polyester the first grand-format dye sublimation coating, usually a liquid that is baked on. printers were designed, there were not If the substrate does not have a polyester many print head choices that were able coating, then the process will not work. to run water-based inks. Responding to Natural fabrics such as cotton and silk demand, paper manufacturers have cre- require different processes, such as an ated papers that run smoothly through acid or reactive ink. a printer, even with high ink loads at industrial level print speeds. Also, there are Q. Why use dye sublimation as many more print head choices that are opposed to other printing methods? aqueous compatible. A. Overall, dye sub’s advantage over Coatings vary depending on the UV-curable, latex or solvent printing manufacturer and ink. Different papers is the ability for the fabric to have the all have their own characteristics to hold same feel, or “hand,” which adds to the and release inks. Clay coated paper seems high-end perception of the product. Put to work best with water-based inks. simply, the end result is by far better in Use INFO # 97 SIGN & DIGITAL GRAPHICS • July 2012 • 43

SBJUL.indd 43 6/15/12 11:26 AM look and feel because the ink is infused into the fibers of the substrate itself, as opposed to a pigmented ink that builds up on the fabric. This level of saturation produces superior output. Another important benefit of the ink being infused directly into the fabric is that without any additional surface protection, the image is now permanent and cannot be washed away, rubbed off or otherwise removed from the fabric. UV, however, is the most versatile of Although the dye sublimation field is growing, there is a perceived high cost of entry and these other ink technologies. It adheres steep learning curve because of the complexity of the process. (Photo courtesy Dave King) well to a wide variety of substrates, including fabric, but it does change the feel of the material. Latex is similar to UV except that it can produce better, UV Inks for dye brighter color on textile than most DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL sublimation can printers. It can change the hand of the be water-based, material, but not to the extent that UV oil-based or solvent based. does. However, a latex printer must be (Photo courtesy slowed down and print many more passes Sawgrass) to achieve the same color as a dye sublimation print. Solvent inks (pigmented inks not to be confused with solvent- based dye sublimation ink) require the material to be coated with a receptive layer for the solvent ink. This can change the hand of the material as well. In addition, solvent output generally produces a less saturated image than the same print with dye sublimation.

Q. If someone wanted to get started in dye sublimation, what equipment would be required? A. Basically you need a printer, some sort of heat press to sublimate the ink and some finishing equipment. In the U.S. you will find about six manufacturers offering printers. There are really three types of printers: all-in-one units with a built-in fixation heat press; printers that just print either transfer or direct; or in some cases, both. The all-in-one units are designed for direct print only. Some of the separate printer/ press units are transfer only and some separate printer/press units can produce graphics with either the transfer or di- The end result of dye sublimation is a high-quality look and feel because the ink is infused into the fibers of the substrate itself, as opposed to a pigmented ink that builds up on the rect method, depending on application fabric. (Photo courtesy Tex Visions) and the type of output required. Then

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SBJUL.indd 44 6/14/12 3:46 PM there are a variety of xation units, from small clamshell heat presses where pressure is applied manually (think T-shirt shop), to industrial sublimation calendars for roll-to-roll grand-format machines. Lastly, there is the nishing equipment such as sewing machines. We are going to get into this in more depth in the future, but basically those are the three big components.

Q. Why do you think adoption of this process has been slower in the U.S. than in Europe? What are the barriers to trial? A. In my opinion there are two reasons: First, the perceived high cost of entry and steep learning curve because of the complexity of the process. Secondly, nishing. On the rst point, equipment and materials are expensive but the margins are much higher. Because of the complexity of producing dye-sublimated graphics and the cost of the materials themselves, the selling price of fabric per square foot can range from $7-$10, which is greater than vinyl by a dollar or two. In other words, printing businesses stand to make a lot of money and the dye sub market remains on a healthy upswing. It is less competitive than say banner printing, which has become somewhat commoditized. In the long run, transportation, handling and overall management of fabric is less costly as well, which is attractive to end-users. On the second point, nishing takes people out of their comfort zone. There is a general lack of education in our industry about sewing, appropriate setups for sewing equipment, supplies like needles, threads and the various types of sewing machines. This has left many in our industry apprehen- sive about taking the rst step into the dye sublimation business. However, the market is wide open with great opportunity for print shops to increase their margins, differentiate themselves, and remain competitive. SDG

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SBJUL.indd 45 6/14/12 3:46 PM SBJUL.indd 46 DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS Entering thedyesublimationmarket 46 • By Am (Photo courtesy ofBrandImagingGroup) (Photo courtesy The PrinterEvolutionEvo33hashelped BrandImagingGroupbreakintonewmarkets. Your Services Diversifying J uly 2012• a nd a

K. K. SIGN &DIGITAL GRAPHICS M cGror y Evo33, asolvent when BrandImagingGroupfoundthe However, thatallrecently changed machine attherightpricethattime. says, buttheshopcouldn’t findthe right into dyesublimationprinting, Snoyer its productofferings, itdecidedtolook Group wasreadytoonceagainincrease a latexor had tobeonacoatedfabricthrowninto it, orwe werelimitedbythefactthatit fabric thatwouldwrinkleifyoufolded tions before, butitwasalwaysonacoated with adyesublimationprinter. market inthesamewaythatitcannow the past, it hasn’t been able to serve the dabbled into the trade show market in says. While Brand ImagingGrouphas Group canincreaseitspresence, Snoyer lar, isanareawhereBrandImaging lowed thecompanytoexpanditsreach. at thebeginningof2012, whichhasal- Group broughttheEvo33intoitsshop market enhancements. Brand Imaging and grand-formatprinterswithafter- PrinterEvolution, aproviderofwide- built into a dye sublimation printer, by B Predators duringthe on a large project for the Nashville because ofthecolorpop.” us. These printsjustlooksomuchbetter it’s opened upthatpartofthemarketfor and such as engraving, architectural signage a widevarietyofsignageapplications, and the company has gone on to include adopter ofdigitalprintingtechnology, Brand ImagingGroupbecameanearly owner ScottSnoyer. Bythelate1990s, start in1994asavinylsigncompany, says franchisee in Antioch, Tenn., firstgotits Around 2007, whenBrandImaging “We did a lot of trade show applica The tradeshowmarket, inparticu- Brand ImagingGrouprecently took munications providerand FastSigns rand ImagingGroup, avisualcom- ADA signage. UV printer,” Snoyersays. “So Amanda be contactedatwww. lance writer. She can is aDenver-based free- Amanda VUTE NHL K K McGrory.com. . McGrory k machinere- playoffsthat 6/14/12 3:54PM - Showcase Your Work in the Industry’s Premier Monthly Publication

Brand Imaging Group created this dye sublimated T-shirts to promote the Nashville Predators during the NHL playoffs. (Photo courtesy of Brand Imaging Group)

sublimation process on the Evo33 is similar to standard lamination, but it does take some practice to make sure the ten- sioning and loading are done correctly. “It is a lot of skill, but it’s also a little bit of art,” Snoyer says. “These are the things you talk about while you’re get- ting trained, but it takes a little practice. That’s where the skill and the art form This banner was created by the dye subli- come in.” mation method. (Photo courtesy of Brand Imaging Group) Snoyer nds that fabric manufacturers are more than willing to provide sign shops with free product rolls as they mas- ter their dye sublimation skills. Fabric it could not have completed without the manufacturers understand that there is new dye sublimation equipment, Snoyer a learning curve, and mistakes are bound says. To support the team, Brand Imaging to happen during this process. Group decorated a large Musica statue In Snoyer’s experience, the image- in downtown Nashville with T-shirts fea- focused clients are more likely to be turing the Predators’ “Stand With Us” interested in dye sublimation printing, slogan. Brand Imaging Group printed he says. Because of the way dye sublima- the T-shirts, which were 6 feet by 7 feet, tion ink embeds itself into the fabric, the on stretchable fabric, and Velcro was graphics are more vibrant and intense. sewn underneath the arms and all the “It’s really easy to sell dye sublimation way down the sides in order to get them to those clients that want a sophisticated over the statue’s heads. look,” Snoyer says. “You can show them “We couldn’t have done that project that they can have vinyl graphics or this with direct printing because we had to brightly printed, sharply colored image use a stretchy fabric,” Snoyer says. “It’s on fabric; it’s just a much richer look.” really helped us offer a better product P. O. P. signage is an area that espe- and do different projects that we couldn’t cially focuses on high-quality images, deadline: do before.” and while Brand Imaging Group hasn’t october 8, 2012 Of course, entering a new market yet targeted that sector for dye sublima- presents its own challenges, especially tion printing, it plans to start in the near For complete contest rules when it comes to learning a different future. Moving forward, Snoyer expects and an entry form go to technology, and this was true for Brand his new dye sublimation printer to help Imaging Group when it brought the new his business grow. www.SDGmag.com dye sublimation printer into its shop, “We’re very happy with it,” Snoyer Snoyer says. Although Brand Imaging says. “Our business is growing because worked with the transfer process in we’re always adding services, and this has the past, it took some time to learn the helped us break into new applications machine’s speci c intricacies. The dye and markets, so life is good.” SDG

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SBJUL.indd 47 6/15/12 9:29 AM Breaking Down Dye Sub, Part 2

SO MANY FABRICS, So Little Time

In the world of dye- Michael Syverson has been in fab- sub printing, choosing in the printing industry for Crics, inks and printers, have made the the right fabric can be almost 20 years, at the fore- wide-format textile printing market one front of the pivotal time of of the fastest growing segments in digital daunting analog to digital conversion. printing today. It is estimated that the Syverson worked for EFI- volume of graphics printed on fabric will BY MICHAEL SYVERSON, VUTEk for 10 years and was instrumental more than double from 2011 to 2014. COMPILED BY MARILYN DAVENPORT in the development and rollout of ve indus- And most of that printing will be done trial inkjet printing devices, helping to create through dye sublimation. GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL and re ne many techniques that were critical This is the second in our five-part to successful print through digital methods. series that explores the intricacies of dye Marilyn Davenport is the Public Relations sublimation with guest expert Michael director for Global Imaging Inc. Syverson, Director of Special Projects

Fabrics are versatile, lightweight, have a wide range of applications and provide a high quality look and feel.

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SBAUG.indd 33 7/13/12 3:53 PM at Louisville, Colo.-based PrinterEvo- lution. Mike has been in the printing industry more than 20 years, and was an applications specialist on the VUTEk project team when it unveiled its first grand-format dye sub printer in 2001. In this article, we will delve into the world of substrates, primarily fabric, from polyester to natural fibers to other materials. Subsequent articles will address heat presses, finishing, marketplace economics and workflow. We asked Mike the following questions: With the Evo33 from Q: Aside from fabric, what are some PrinterEvolution, fabric images other substrates that can be used? can be created A: Most anything can be sublimated, printing direct or via transfer but it has to have a polyester coating. paper using Dyes are formulated to penetrate poly-

DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL environmentally friendly ester. When polyester gets heated, the AquaSub33 molecules expand, allowing the dye to water based dye seep in. Poly-coated mugs, ceramics, sublimation inks. The unit features wood, glass, specially prepared mouse 10pL, variable pads, and many other similar types of drop, greyscale printheads, and products can be printed with dye sub- offers production limation technology. There are several speeds of up to websites dedicated to providing these 1,200 sq. ft/hr. coated “blanks” for companies producing these types of products. By far, fabric is the most widely used, offering the industry many textures and finishes, versatility and flexibility that provide customers with high quality results.

Q: Tell us about the different types of fabrics and their applications. A: Basically there are two types of fabric, woven and knit. Woven fabric is more stable in terms of its stretch characteristics, but tends to fray making finishing more difficult. Woven fabrics generally do not have much stretch unless they are woven with elastic or spandex type thread. Knit fabrics will have a bit more stretch by nature than a woven fabric and they do not fray which eases the finishing, but knitted fabrics can be more expensive because they are more labor intensive. A very common material for hang- Recent advancements in fabrics, inks and printers, have helped grow the burgeoning wide- format textile printing market. ing signs and banners that need weight is poplin. Poplin is usually a knit fabric, although some manufacturers have a

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SBAUG.indd 34 7/13/12 3:53 PM Fabric manufacturers and suppliers are continually evolving their products to meet customer demand for environmentally friendly and ame-resistant fabrics.

woven version. Poplin drapes nicely and ame-resistant fabrics that have excel- especially true in the big box retail arena tends to be slightly heavier. Soft knits lent stretch and recovery characteristics where companies want eco-friendly are typically of a lighter weight and and little to no shrinkage. bers woven into their fabrics with cus- have more stretch to them, making them Some fabricators are actually design- tomized specifications. There’s also a ideal for overhead signage, tension fab- ing fabric for clients based on how they growing trend in specialty upholstery ric applications like exhibition graphics, want it to look and feel, stretch attri- projects and interior design elements. and framed signage for a smoother look butes, shrink level and opacity. This is Everyone from architects to hotels to and feel. Flag material has an open weave so air passes through it. Flag is typically used for outdoor applications, such as a teardrop display or actual ags. Gener- ally, this material is printed so that ink will pass through to the back side (strike- through) so the graphic is mirrored on the reverse side for double-sided applications. Because of the need for strike- through, it is usually printed directly to the fabric as opposed to transferred. If a customer wants a lightweight double- sided sign or banner, this would be a good choice. Satin is a closed, tighter weave with a gloss or sheen to it. It drapes beauti- fully but can be expensive. Satin is most often used for P. O. P. displays and indoor applications. PolySilk is a versatile, light weight material that is growing in popularity for its translucent, draping applications. It can be bold and bright but it’s not as durable as the heavier materials due to its lightweight weave. Gaming felt is another type of fabric used for specialty applications like pool tables or poker tables with graphics. This is only a small sampling of the different fabrics that are available. There are several manufactures that make many different products for virtually any application (see chart, page 38).

Q: What are the trends in new fabrics? A: The macro-trend in general is a fabric that is becoming the preferred choice over rigid or vinyl substrates for large and grand format applications. Fabrics are versatile, lightweight, have a wide range of applications and provide a high-quality look and feel. They are easier to install and remove and they are more cost effective to ship. Fabric manufacturers and suppliers are continually evolving their products to meet customer demand for environmentally friendly, Use INFO # 103 SIGN & DIGITAL GRAPHICS • August 2012 • 35

Untitled-1 35 7/13/12 5:14 PM mom-and-pop interior decorators are using fabric for custom-printed furni- ture, draperies, shades, wall hangings and other indoor applications.

Q: What are some tips for working with various fabrics? A: The endless fabric choices make working with them confusing. They all have different characteristics that need to be addressed when printing and sublimating through the calendar. For example, fabrics with a great amount of stretch need special attention on the When selecting transfer paper, you must setup of the printer in order for the mate- ﬁ rst make sure the paper’s coating is rial to ow through the machine with compatible with the ink technology being used. Different papers that are consistent surface tension. Flag materials compatible with either oil, solvent or are typically direct printed to maximize water based inks. the strike-through to the reverse side (Left) The newer water- based, eco- of the material. When transferring to friendly textile inks offer improved depth ag, it is virtually impossible to get over of color and consistency. 50-75 percent strike-through. By printing direct, you can easily achieve 90-100 percent. It is important to control the amount of ink printed on the fabric as too little will not penetrate deep enough and too much can cause the ink to bloom on the fabric (dot-gain). Many knit fabrics are relatively easy to print, whether transferred or direct. Again, ink load is critical for direct print. When sublimating fabrics, it is important to have your settings dialed in at the calendar (contact time, temperature and blanket pressure). Once these settings are in place, make sure they are maintained as changes in these calibrations can alter how the dyes are sublimated and affect color.

Q: Are there certain media transport systems that work better with different fabric types? A: There are different philosophies as to media transport, each with their own advantages depending on the application. Many systems use a single nip for the material as it is loaded into the printer. This is a very sound system and can handle a wide array of fabrics and paper, but it lacks the robustness of larger, more industrial systems.

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SBAUG.indd 36 7/13/12 3:53 PM Introducing the new JV400LX Series of wide-format latex printers.

use a dual pinch roller system with tension applied to the material so it can feed Latex Unleashed very evenly and consistently through the X INNOVATIVE INKS printer. When direct printing to fabric, Utilizes the latest in latex ink formulation and offers a these systems can have some difficulties. A third system utilizes a flat sticky wider range of media choices with the use of WHITE ink belt (similar systems are seen on some and lower operating temperatures. flatbed UV printers). This works great X ECONOMICAL for direct-to-fabric solutions, but often Requires only standard 110 volt electrical connections for times cannot be used with the transfer operation. It saves you money due to lower power consumption and method of sublimation as the sticky belt installation costs. Realize lower production costs with long lasting can tear the transfer paper. piezo print heads that output at a speedy 194 sq.ft/hr. X ECO-FRIENDLY Q: What are the most important con- With low VOC latex inks, these printers can operate anywhere siderations when selecting fabric? and the 600ml ink cartridges are reusable. A: The most important thing in choosing a fabric is to understand how it will be used. What’s the application? Do you need it to be translucent? How will it be lit? Will it be hanging, draped or stretched? You want to avoid fabrics that curl and consider the shrinkage factor. Suppliers should have a good consistent shrinkage rate for their materials and it shouldn’t exceed 1-2 percent. Cost is another factor and sometimes buying the less expensive option could end up cost- ing more because the quality of the fabric may be inferior. There may be more dirt spots, or runs in the fabric. In addition, it may not be pre-shrunk or flame-retar- dant. Finally, lower cost options could have much more unpredictability from lot to lot.

Q: How does printing equipment OUTDOOR VEHICLE EXHIBITION affect fabric selection? SIGNAGE GRAPHICS & EVENT RETAIL POP INTERIOR DECOR A: Your equipment can also influ- ence the choices in fabrics. If you have a printer that can only print direct to textile, for example, you need to be very aware that some fabrics may not print

well, (especially at wider widths) even AUG 16-18, 2012 LONG though they may be available with a BEACH! direct to textile coating. It is important BOOTH 413 AUGUST 16-18 to speak with your suppliers about your applications and your equipment so they mimakiusa.com can recommend the best solution for

your needs. EMAIL INFO [email protected] ATL 888-530-3988 BOS 888-530-3986 CHI 888-530-3985 LA 888-530-3987 Q: Are there specific inks that work

better with fabric than others for both © 2012 Mimaki USA, Inc. direct and transfer printing? Use Info # 148 SIGN & DIGITAL GRAPHICS • August 2012 • 37 Mimaki JV400_2/3_SDG0812.indd 1 6/29/12 2:04 PM

Untitled-1 37 7/16/12 3:01 PM A: Dye sublimation is designed to work around polyester materials. When printing to a different material, such as silk, cotton, nylon or linen, other ink technologies need to be considered. Cottons and linen for example, require reactive dye-based inks. The chemical properties in the dyes and the cotton or linen fibers create a very strong bond for wash fastness and color fastness. After printing, the fabric needs to be steamed and washed for the ink to bond to the fabric. Silk, nylon and wool require acid dye inks. These are printed in a very similar fashion and also require steaming and washing after printing to affix the colorant to the textile. Both of these technologies yield very good results in terms

DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL of color brightness and maintaining the hand of the fabric. An alternative to these technologies is printing with a pigment- The large number of fabric choices make working with them confusing. Each has different based ink (such as latex, UV curable or characteristics that need to be addressed. solvent-based pigmented ink). Pig- mented inks provide great flexibility as you can print on most any of the fabrics, Polyester-Based Fabric Sources however, some of them may Company Fabric Types Web Site need to be coated (in the Made in the US: BannerLux, pop up display, table Aberdeen Fabrics, Inc www.aberdeenfabrics.com case of solvent, for example). cover, soft knit, flag and more Additionally, pigmented Arlon Poly banner, blockout and poly mesh banner www.arlon.com inks will change the hand of Aurora Specialty Canvas, Chintz, sateen, muslin, poplin, taffeta, more www.auroratextile.com the final product, which may Bainbridge Int’l. polyester and nylon, banner, mesh www.bainbridgeint.com be very important, especially Berger Textil flag, satin, canvas, banner, and stretch fabrics www.bergertextil.com California Combining Lam Tex Supersmooth, doubleface www.californiacombining.com in the case of a stretch fabric Cooley Group Coolflex, Enviroflex, WeatherTyte www.cooleygroup.com application. DAF Products Screen, MaxVue, Frontlit, Mesh www.dafproducts.com Dazian Celtic, Eco, heavyweight Celtic, stretch, blackout, more http://dazian.com Q: What should a print DHJ International Rang of poly-based fabrics, tent and stretch materials www.dhj-international.com shop owner look for in Fisher Textiles billboard, stretch, duck, poplin flag, canvas, more www.fishertextiles.com choosing a dye sub trans- Glen Raven Poly Oxford White www.glenraven.com fer paper? Herculite Products Bantex, banner, flag, mesh TruColor, canvas, more www.herculite.com A: There are several Ibena Flag, blockout, DyeSub, GlossyFab, PES Deco www.ibena.de things to consider when MarChem CFI Holiday, Odyssey, Softouch, Top Gun, Top Notch www.marchemcfi.com choosing a transfer paper. Mehler Texnologies polyester-based banner and industrial fabrics www.mehler-texnologies.com First, make sure the coat- Naizil Inc. woven polyester banner materials www.naizilcanada.com ing is compatible with the Neschen Americas DirectTex flag, poplin, satin heavy, banner, more ww.neschen-accutech.com ink technology being used. Obeikan Cybertex, Obeflex blockout, frontlit, mesh, more www.obeflex.com Many manufacturers make Pacific Coast Fabrics Denier Poly, Corsair brushed, flag, taffeta, more www.pacificcoastfabrics.com different papers that are Seattle Textile Co. Digitex, Tex banner, eco, banner, blockout, more www.seattlefabrics.com Serge Ferrari North Am. Decolit, mesh, Exploit, Sign-it, Vision mesh www.ferrarisign.it compatible with either oil, SuperTex Fabrics Sylutex frontlit, mesh, tight weave www.supertexpvc.com solvent or water based inks. UltraFlex Artex, BioFlex, blockout, banner, mesh, poplin, more www.ultraflexx.com The goal of coating is to Value Vinyls Ad-Flex, EcoLogic, Freedom, Grand-Flex, mesh more www.valuevinyls.com minimize ink absorption Verseidag Seemee US Insight, Medallion, Poly heavy/light, flag, more www.seemeeus.com in the paper by holding as

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SBAUG.indd 38 7/17/12 2:27 PM The newer water- based, eco-friendly inks are more widely available for grand format printers. These inks have also improved in depth of color and consistency.

much ink as possible in the coating. The recommending products they have tested The newer water- based, eco-friendly better coatings can hold more ink dur- on their equipment. inks are more widely available for grand ing printing and release more of that ink format printers. These inks have also into the fabric when sublimated. Gener- Q: How have printing and ink tech- improved in depth of color and consis- ally this yields more color vibrancy, but nologies contributed to the growth of tency. Advances have also been made in it is somewhat subjective. digital textile printing? coating technologies for direct printing. Another thing to look for when A: There’s been an increasing demand There seems to be more communica- choosing a paper is how it runs through for printing equipment particularly in the tion between the mills and the ink manu- the printer. You want a paper that doesn’t 10ft. wide textile market. Manufacturers facturers in how they develop effective cockle and will run through the printer have started providing more options coatings for fabrics. The various manu- smoothly. If the paper cannot absorb to customers interested in direct and facturers of printers, supporting devices much ink, it will tend to cockle, poten- transfer printing with equipment that and consumables are constantly innovat- tially causing a head strike. Large shifts can offer both and is faster and more ing in all of these areas as this is a fast- in humidity can also cause problems with efficient. Print heads have improved growing segment of the textile printing the paper by making it unstable on the significantly in the past several years. business. SDG printer and more prone to wrinkling on Print heads with a fixed, binary droplet the heat press. It is important to keep of 80 picoliters (pL) have been replaced humidity levels stable within your facil- with variable drop heads with droplets ity. Most of the printer and heat press as small as 6-10 pL. This has resulted in manufacturers have a lot of experience greater sharpness and detail, finer lines, with different papers. When choos- and overall, better image quality with ing one, they should be able to help by excellent color gamut.

Use Info # 146

SIGN & DIGITAL GRAPHICS • August 2012 • 39

Untitled-1 39 7/13/12 5:15 PM Breaking Down Dye Sub, Part 3

Feel the Heat

Calendars and heat Michael Syverson has been n the dye sublimation world, heat presses are key to in the printing industry for is king. In order to fixate the dyes to sublimation success almost 20 years, at the fore- Ithe fabric, they must first be heated at front of the pivotal time of 400˚F for at least 30 seconds. For that analog to digital conversion. you need a good quality heat press or By Michael Syverson, Syverson worked for EFI- calendar unit. Any variation in consis- compiled by Marilyn VUTEk for 10 years and was instrumental tency of time, temperature and pres- Davenport in the development and rollout of five indus- sure can impact color, ruin the job and

DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL trial inkjet printing devices, helping to create in the end, cost you more money. Thus and refine many techniques that were critical understanding the equipment necessary to successful print through digital methods. to achieve effective dye sublimation and Marilyn Davenport is the Public Relations rich output is one of the most important director for Global Imaging Inc. steps you can take.

Understanding the function and applications of the heat press and/or calendar unit is crucial to achieving beautiful dye-sub output such as this. (Image courtesy of Mimaki)

40 • September 2012 • SIGN & DIGITAL GRAPHICS

SBSEP.indd 40 8/14/12 10:50 AM This is the third in our five-part Discover the versatility of FlexCoat-EZ™ series that explores the intricacies of dye sublimation with guest expert EZ Printing EZ Cutting for Display FlexCoat-EZ is coated with a printable surface* Because of its revolutionary coating, curling and rough edges Michael Syverson, Director of Special compatible with wide format inkjet, commercial are eliminated, and die cutting blades do not gum up. digital, flexo, offset, and screen printers. Projects at Louisville, Colo.-based If you’re ready to produce EZ magnets, then contact us today PrinterEvolution. Syverson has been in EZ Magnetizing at 800.543.4426 FlexCoat-EZ can be purchased either magnetized the printing industry more than 20 years, or unmagnetized. Our selection of hand-held and and was an applications specialist on the automated magnetizers allow easy magnetization. VUTEk project team when it unveiled EZ To Order Buy online at www.flexmag.com its first grand-format dye sub printer in or scan our QR code. 2001. In this article, we will discuss the * Patent Pending White Coating heat press and calendar equipment that is Use Info # 144 used in the signage and graphics industry and other applications. The final articles in the series will explore finishing, marketplace economics and workflow. Buying New Q: What does a heat press/calendar machine do, and why is it important in the dye sublimation process? A: The primary purpose of a heat Equipment? press or calendar is to facilitate the sublimation of dyes into fabric. All of these devices have a heated element and some sort of feature to apply pressure to the Contact Global Imaging. transfer paper and fabric to convert the ink to gas (sublimate) and have it per- Leading U.S. Distributor for Wide meate the fibers of the polyester fabric (or polyester coating). This is a required Format Equipment, Supplies and step in the dye sublimation process as Technical Services. the dyes are not fixated until they have been heated at a certain temperature for a certain amount of time. www.globalimaginginc.com 800.787.9801 Q: The terms “heat press” and “calen- See us at in the PrinterEvolution BOOTH dar” are frequently interchanged. Can SGIA #900 you explain the difference? Our Brands • Everything You Need for Wide and Grand Format Success A: Although the function of a heat press and a calendar in dye sublimation are basically the same—fixate the colors into fabric—the fundamental difference is that a calendar is designed for Use Info # 88

SIGN & DIGITAL GRAPHICS • September 2012 • 41

SBSEP.indd 41 8/30/12 12:05 PM roll-to-roll sublimating, typically for rolled textiles and more commonly used in the signage and graphics industry. A heat press is designed for one-off images. Heat presses come in many different sizes and designs depending on the specific application. There are flatbed- heat presses that can be used for one-off flat prints such as mouse pads, glass or ceramic tiles, or other specialty small graphics. There are also circular heat presses with a curved heating element for imaging on to a mug, for example. This beltless calendar is designed specifically for direct dye-sub printing and doesn’t require The most common heat presses are transfer paper. (Image courtesy of Global Imaging) clamshell and swing-away units. A clamshell opens from the rear and the platen opens up at an angle to allow access to your image area. This is good for small imprintable items and garments.

DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL The swing-away style raises and low- ers the platen vertically and swings to one side and is usually used for rigid surfaces. Some of these presses are automatic in that they will close and open on a timer so you have precise control of your transfers. Many units are fully manual. These are much Smaller more popular as they require a lower clamshell-style heat presses, such initial investment. Finally, there are units as this hand-operated designed for transferring onto t-shirts. model are ideal for one- These have a shuttle type system so you off production of smaller imprintable items. (Image courtesy of U.S Cutter) can stage a t-shirt on a jig while one is transferring. If you are doing short-run Calendar equip- t-shirts, this is a good way to produce this ment, like this type of product. Klieverik model GTC 81/3400, There are many choices for calendars is designed to as well. They are available in several dif- transfer sublimate onto ferent widths and can come with many rolled fabric options, such as a staging table for setting substrates. Fabric must be up flexible sheeted goods, multiple rolls, heated at 400˚F different diameter drums, auto shutdown for at least 30 timers, blanket or belt lengths and a va- seconds in order for dye-sub inks riety of other enhancements. There are to fixate into the also beltless calendars specifically for di- fabric. (Image courtesy of rect printing that don’t require transfer Global Imaging) paper. You may need protection paper however if you’re working with delicate fabrics. Although these are less expensive machines, the results cannot be compared. The transfer paper produces a higher quality image, with sharper, deeper color output.

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SBSEP.indd 42 8/14/12 10:59 AM Q: What is a flatbed heat press, how does it work, and what applications is it best used for? A: Flatbed heat presses are designed for sheeted applications only. The presses can range in size from small 11" x 14" presses to 4' x 8' presses with two full size beds. They usually have a bed where the substrates and transfer paper is laid out. Above the bed is a heated platen that is lowered on the substrate. This bed is heated to approximately 400˚F and is lowered on to the substrate with an amount of pressure sufficient enough to sublimate the inks into the donor substrates. The pressure and time can be changed based on the substrate. Some of these devices are manually actuated while some of the more sophisticated devices have electronic or pneumatic systems for raising or lowering the platen. Many of the smaller products, such as gifts, promotional items, and specialty graphics Use Info # 102 are imaged with the smaller units. Some larger shops use the bigger presses for higher volume products. A 4' x 8' press can be used to set up 32 12" tiles with one large sheet of transfer paper to create custom tiled mosaics, for example. The Selling Used units with two 4' x 8' beds are designed so you are laying out one print while the other is sublimating, creating a more ef- Equipment? ficient workflow.

Q: What is a rotary calendar and how does it work? What applications is it best used for? GLOBAL Contact Global Garage. A: A rotary calendar is designed for GARAGE output onto flexible substrates, such as The leading worldwide online BUY AND SELL marketplace for buying and rolled fabrics. Its operation is somewhat USED EQUIPMENT similar to a laminator. There is a continu- selling used wide and grand ous blanket (or belt) that wraps around format equipment. a heated cylinder. Fabric and transfer paper are put together and set upon this www.globalgarage.net blanket. The blanket carries the fabric 800.787.9802 and paper and presses it against the heated drum for a given time to sublimate the See us at SGIA in the PrinterEvolution Booth #900 image to the fabric. The blanket also has pressure applied to it against the drum to Our Brands • Everything You Need for Wide and Grand Format Success help facilitate the process. The advantage of this device is that is can be used for high volume rolled goods (and some select sheet materials). Use Info # 159 SIGN & DIGITAL GRAPHICS • September 2012 • 43

SBSEP.indd 43 8/30/12 12:05 PM These illustrations show a schematic of how fabric is threaded through a calendar fixation unit. (Image courtesy of Klieverik)

the speed of the calendar, as fabric needs a certain amount of contact time with the drum to achieve proper fixation. The bigger the diameter, the faster it will produce graphics. How the drum is heated—Most calendar units these days have a drum filled with oil that is heated to approximately

DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL 400˚F. You want a calendar that uses oil because it produces a very even heat This dual swing-away heat press is designed to sublimate onto larger across the width of the unit and the tem- polyester-coated rigid substrates. perature will stay very stable. Calendars (Image courtesy of GraphicsOne) with electrically heated drums can cause hot spots in the fabric and some units cannot keep up with the transfer speed in Because the material is wrapping This is a very important component to terms of heat. Hot spots can cause color around a heated cylinder, items such as use on the calendar in order to extend differences and a variance in temperature coated tiles or other rigid materials can- the life of the blanket and prevent any from the beginning to the end of a print. not be sublimated with this process. For unwanted offsetting of ink onto your The length of the printing blan- rigid materials, you must use a heat press. printed graphics. ket or belt—The longer the belt, the Calendars are ideal for the big produc- steadier it runs through the calendar. tion textile industry as well as large-for- Q: What should a print shop owner The belt will tend to wander and move mat graphics such as exhibition signage, look for when purchasing a calendar which has to be corrected and different banners, exterior and interior design and/or heat press? machines have different ways of handling displays and upholstery. A: There are many things to consider that. Some machines use a pushing and when choosing a calendar or heat press. pulling mechanism that tends to damage Q: What is “protection paper” and For calendars you need to consider: the belt over time. Others use an electri- why is it used? Is it different than The width—The calendar should cal steering arm that moves up and down transfer paper? match up in terms of width with the which doesn’t damage the belt and ex- A: Protection paper, or tissue paper, is output device being used. Calendars are tends its lifetime. used on a calendar or heat press to pro- available in sizes from 64" up to 10' wide. For heat presses, the following areas tect either the drum/platen or the blan- Many shops will purchase a calendar that need to be considered: ket from ink sublimating on to it. It ab- is wider than their current output de- Size of press bed—How large do sorbs excess gasses that do not sublimate vice in the event they decide down the you need the press to be? It again de- into your polyester fabric or coating. If, road to purchase a wider printing depends on the application. for example, you did not use tissue paper vice. Companies will purchase the cal- Heating element—Most heat on the blanket of your calendar and ink endar and keep it many more years than presses use an aluminum upper heating sublimated through the fabric, there is a a printer so anticipated growth should element with a heat rod or heating wire possibility the ink in the blanket would be taken into account when purchasing. attached or cast into it. Make sure the offset back into your fabric the next time Maximum capacity—Calendars heating element heats evenly and can that spot in the blanket wrapped around have a cylindrical drum that is heated. keep consistent heat. Where many heat and came into contact with the fabric. The diameter of this drum determines presses are one-off type machines, it is

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SBSEP.indd 44 8/14/12 11:01 AM easier to maintain heat as you can let the press heat back while you are staging your next print. Warranties—You should expect at least a one-year warranty on your purchased piece of equipment in addition to training and installation.

Q: What is the Black Box equipment used in direct printing? A: This type of device is usually associated with all-in-one units that print and sublimate in one pass. These units have infrared heaters (or similar) that heat the box and start the sublimation process. They have the advantage of not needing a separate device for sublimation, but do have limits. Some of these units cannot sublimate the ink completely and may require the finished graphics to be washed after printing/sublimating to prevent any of the un-sublimated ink running on the Use Info # 75 finished graphic. Also, due to the nature of these units, transfer printing is usually not possible due to the architecture of the printer/heating element. A calendar or heat press provides the best possible solution for sublimation as it has the Financing ability to apply pressure to the graphics as it goes around the drum (or under a platen). Most of the black box units do not have this ability. Equipment?

Q: How can a shop owner justify the cost of the calendar versus that of a heat press. What are the particular Contact Panoply Finance. benefits? A: The choice between a flatbed Funding options specifically for heat press versus a calendar unit is fairly the wide and grand format market. simple. It really depends on the applications. If a shop owner is producing soft signage (banners, flags, etc.), then a ro- www.panoplyfinance.com tary calendar is the way to go. If a shop 303.339.9832 is producing nothing but small garments, gift and promotional items, then a flatbed press is more appropriate. Several See us at SGIA in the PrinterEvolution Booth #900 shops that have rotary calendars may also

have a small heat press for proofing small Our Brands • Everything You Need for Wide and Grand Format Success files or testing different applications. The smaller heat presses are relatively inex- pensive and cost much less to operate than a 10' rotary calendar. SDG Use Info # 161 SIGN & DIGITAL GRAPHICS • September 2012 • 45

SBSEP.indd 45 8/30/12 12:06 PM Breaking Down Dye Sub, Part 4

Finishing Touch

The finishing depart- Michael Syverson has been can range from seaming and hemming, ment for dye-sub in the printing industry for to adding pockets and grommets. While applications can almost 20 years, at the fore- the options are numerous, the equipment front of the pivotal time of to perform these tasks is also formidable. make the difference analog to digital conversion. Fabric steamers, heat presses, industrial- between a high-end Syverson worked for EFI- strength sewing machines, sergers, weld- fabric graphics job and VUTEk for 10 years and was instrumental ers and seamers all contribute to the one that isn’t in the development and rollout of five indus- successful finishing of soft signage and DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL trial inkjet printing devices, helping to create textiles. By Michael Syverson, and refine many techniques that were critical In Part 4 of our 5-part dye sublima- compiled by Marilyn to successful print through digital methods. tion series, we provide you with informa- Davenport Marilyn Davenport is the Public Relations tion on the various finishing procedures, director for Global Imaging Inc. the equipment available to achieve the best results and ways to determine if a finishing department can contribute to your business success.

Q: What are the advantages of investing in a dye sub fabric finishing department? A: These days, finishing is seen as a necessary part of the dye sub process and a business should consider it seriously if it’s going to get into the game. Adding an internal finishing production area can help retain customers and build loyalty. It alleviates the cost of outsourcing for these services and in the long run, can make a shop owner more money. It also is added value to be able to offer high quality finishing as part of the entire project, saving time as well as the risk of error as Fabric graphics often require some finishing in order to pres- multiple people handle the project if it’s ent well. These famous album ost professional fabric graphic not under one roof. cover designs are printed onto fabric that was then stretched printers understand that there’s over wooden frames. Mmore to a project than just print- Q: What should digital graphics ing. Once you print it, you have to finish and sign shops know if they are just it and oftentimes, finishing techniques starting to explore offering finishing can make the difference between a high- services? end looking product and something that A: Sign shop owners need to under- isn’t compelling enough to compete in stand the equipment requirements for the marketplace. Finishing procedures the various finishing techniques, look at

38 • October 2012 • SIGN & DIGITAL GRAPHICS

SBOCT.indd 38 9/13/12 3:23 PM Finishing Touch

Stretch frame systems such as the Aluvision Frame shown here, is a great way to stretch-mount fabric graphics.

the pros and cons of each piece of equipment, research the pricing, labor and training involved and determine what types of applications they want to pursue, whether it’s large or small scale produc- Use Info # 84 tion. Also a shop needs to have enough space to stage graphics for large applications. The application determines if it is sewn or welded. With dye sublimation, sewing is the most common finishing technique. However, both welding and Buying New sewing have their benefits.

Q: What type of equipment is used in finishing procedures? Equipment? A: Depending on the type of fabric being used, there are required pieces of equipment needed in order to prop- Contact Global Imaging. erly finish the printed graphics. Fabrics made of natural fibers, such as silk, wool Leading U.S. Distributor for or cotton, need to be steamed after they are printed. The steaming fuses the dyes Wide Format Equipment, to the fabrics. Once that is completed, Supplies and Technical Services. the finished fabrics need to be washed before final finishing. With dye sublima- www.globalimaginginc.com tion printing, polyester fabrics need to 800.787.9801 be heat set or transferred on a calendar or heat press after printing. Once this is completed, then the final finishing can See us at SGIA in the PrinterEvolution Booth #900 take place. Most print shops finish fabric graphics by sewing them. There are a variety of industrial level sewing machines on the market today designed for many different Our Brands • Everything You Need for Wide and Grand Format Success applications. The final application and Use Info # 161

SIGN & DIGITAL GRAPHICS •October 2012 • 39

SBOCT.indd 39 9/17/12 10:48 AM A serger sewing machine is also a valuable tool to have for sewing graphics with a heavy duty stitch that can have some stretch. A serger creates a stitch with two, three or even four threads and can also cut the edge of the fabric automatically to create a finished edge. They are also very helpful for adding strength to a seam. Keep in mind that while a serger can do a wide variety of Although more commonly associated with cutting rigid substrates, an X/Y cutter applications, it will not replace a standard can be very beneficial for high-production sewing machine for basic seams, such as needs. Some manufacturers carry special The sewing station is an important part of zippers or top-stitching. blades that will cut fabric very easily, such any sign shop that’s serious about tackling as Zünd’s Driven Rotary Tool (DRT). dye-sublimation work. Fabrics can also be welded, similar to how welded vinyl graphics are created. Although this isn’t as popular as sewing, it can leave a very clean edge for those applications where a sewn edge or seam is not desired. It can also create a very

DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL strong bond that can be more durable than the fabric itself. Another aspect of finishing is the cutting of the fabric graphics. Most graphics are trimmed manually with scissors. For high production needs, an X/Y cutter can be very beneficial. Some manufacturers carry special blades that will cut fabric very easily, such as Zünd’s Driven Rotary Tool (DRT). An important thing to note when cutting fabric is that the system is designed to take fabric stretch Fabrics can also be welded, similar to how welded vinyl graphics are created. Although this isn’t as popular as into account as it registers the cutting sewing, it can leave a very clean edge. geometry with the actual printed graphic. Grommets These flatbed cutting tables are very ver- are not often satile, not only for fabric graphics, but used with fabric applications, but can install location will determine the level of finishing for cutting of all graphics produced in come in handy. This needed for the graphic. For example, if a graphic is a shop. tool is commonly used to set grom- going to be mounted in a stretch frame with a silicon Finally, all shops should have a hot mets into vinyl bead, then the fabric is usually cut with a hot knife knife for cutting graphics that cannot or banners. and the silicon bead is sewn into the fabric. This may not need to be hemmed. A hot knife application does not allow the fabric to be hemmed basically has a blade that is heated above as the hem would make the edge too thick to fit in the melting point of the polyester fabric a stretch frame. and sears the edges as it cuts the fabric. If a graphic is going to be used in a double-sided This can be particularly useful for woven application (such as a hanging aisle marker for a trade- graphics that tend to fray after being cut show), then the graphic is usually printed twice, subli- with a scissor. mated and has a black fabric (or other blockout layer) sewn in between the two facing graphics so no light Q: What should you look for when passes through the finished product. These require buying sewing equipment for dye some skill during sewing as you are sewing three layers sub finishing? together. Heavier duty applications such as this may A: It really depends on the needs of require a double stitch. There are sewing machines the company. A shop that only does a that have this capability automatically built-in. few sewn products a day should consider

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SBOCT.indd 40 9/13/12 3:24 PM a low volume solution for their sewing needs. A standard sewing machine and serger in this category can be obtained for under $800. If a PSP is a very high- volume shop, then they should consider an industrial solution for their needs. Equipment in this category can cost from $6,000 on up. There are benefits for these industrial machines as they will last a lot longer in a high production environment and can often have features not available in the lower volume segment. Both automated and hand-action grommet machines are available. Which is the best choice? Both pieces of equipment are valuable and again, the choice really comes down to the volume of work in the shop. A high-production facility will more than likely have an automated grommet machine that will automatically punch and grommet the fabric, but a smaller Use Info # 102 shop with less volume can function just as well with a hand-action, manual grommet machine.

Q: How can this equipment increase productivity and profit? Selling Used A: Higher-end sewing machines are faster and can increase productivity, but you still need talented sewers to provide damage control and produce the high- Equipment? end finished product that customers expect. Additionally, by bringing the finishing in-house, a print provider can fur- Contact Global Garage. ther control costs, scheduling and man- age the entire project to ensure a high The worldwide marketplace for level of quality and increase efficiencies. buying and selling used grand Q: What are the various finishing format equipment. options and their applications? A: Finishing techniques really depend www.globalgarage.net on the final application and need. Here are some common ones: 800.787.9802 Pole pocket—mostly used for hanging banners. The poles are inserted in the See us at SGIA in the PrinterEvolution Booth #900 top and the bottom. Equipment: sewing machine or welder. Grommets—not often done in fabric, mostly used for vinyl. Equipment: grommeting machine. Our Brands • Everything You Need for Wide and Grand Format Success Hems—for finished edges, seams Use Info # 159 SIGN & DIGITAL GRAPHICS •October 2012 • 41

SBOCT.indd 41 9/17/12 10:49 AM 8-29 FlexCoat Resize ad.pdf 1 8/29/12 4:28 PM

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and multiple panels. Equipment: sewing machine, welder. Stretch Frames—sewing of silicon beads that mount to a channel and snap into a frame. Aluvision makes the frames and sells the beads. With stretch fabric DELIVERED! you want to avoid ripple or waves. A lot FlexCoat-EZ – engineered to eliminate the hassles associated of the same techniques are used on fabric with flexible magnetic printing and laminating – is now available and vinyl in this application. Equipment: at a special online price. Get a 50-foot roll of 0.030" x 24 5/16" FlexCoat-EZ for only $85, with FREE delivery anywhere sewing machine and the frame. in the U.S. Now you’ll be able to expand or create a new revenue stream Q: What are some of the challenges with magnetic media, using your current printing technology. FlexCoat-EZ is compatible with inkjet, digital, flexo, offset, in running a finishing department? litho and screen printers. A: One big challenge is finding skilled Thanks to FlexCoat-EZ’s revolutionary coating*, hassles like curling labor that can sew. Another challenge is and gummed-up cutting blades are eliminated, so you can easily produce magnetized signs, posters, business cards, displays, calendars and more. having the space to stage large graph- It’s as easy as print, magnetize, display! ics. When bringing in fabric printing Go online now to take advantage of this offer at www.flexmag.com (along with large banners in general), it or scan our QR code below. is important to properly plan the space Credit cards accepted, there’s no minimum order, so there is enough room to stage graph- and we’ll ship to you the next business day! Made in the USA ics for finishing. In addition, if the final *Patent Pending White Coating graphics are being used on a stretch

frame, it is advisable to stage the frame Use Info # 144 and attach the graphics to the frame for proper fitment. Many applications are 3-D in nature so time needs to be spent in creating the graphics and the seams the final image lays properly on the 3-D frame. The Financing stretch of the fabric needs to be taken into account, along with the location of the seams and how it will attach to the frame (Velcro, zippers, silicon beads, etc.) Equipment?

Q: What are some of the trends in the finishing arena? Contact Panoply Finance. A: As far as trends go, it seems that many PSPs are continuing to look for Funding options specifically ways to minimize the steps in the production process with equipment that is for the wide and grand faster and used for various applications. format market. Shop owners want consistency, reliabil- ity and more and more are bringing fin- www.panoplyfinance.com ishing in-house to cut down on outside 303.339.9832 sourcing and fulfillment. Many PSPs are looking at ways to finish graphics more efficiently to improve their turnaround See us at SGIA in the PrinterEvolution Booth #900 time and reduce labor costs. Equipment such as faster sewing machines, automated x/y cutters with fabric attachments and welding units designed for textile are some of the products shops are looking Our Brands • Everything You Need for Wide and Grand Format Success to invest in for future. SDG Use Info # 88

SIGN & DIGITAL GRAPHICS •October 2012 • 43

SBOCT.indd 43 9/17/12 10:50 AM Breaking Down Dye Sub, Part 5

Dye Sub Marketplace and Economics

Taking advantage Michael Syverson has been hen does it make sense to include of the $165 billion in the printing industry for Wdye sublimation as a part of your printed textile market almost 20 years, at the fore- business? Recognizing the growth in the front of the pivotal time of digital textile industry and the increasing analog to digital conversion. demand for the rich, high-quality appeal By Michael Syverson, Syverson worked for EFI- of fabric and its efficiencies in shipping compiled by Marilyn VUTEk for 10 years and was instrumental and handling, it may be now. Davenport in the development and rollout of five indus- This is the final installment in our

trial inkjet printing devices, helping to create comprehensive series on dye sublima- GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL and refine many techniques that were critical tion, its benefits, intricacies and the to successful print through digital methods. technologies associated with it. In this SDG Marilyn Davenport is the Public Relations final article we present an overview of director for Global Imaging Inc. the marketplace and it’s economic impact to help you formulate your future plans and make an informed, intelligent deci- Less than 1 percent of the $165 billion printed textile market is currently digitally printed. With the improved inks and printing systems available today, textile sion about the growth strategy of your printing represents an excellent opportunity. business.

SIGN & DIGITAL GRAPHICS • November 2012 • 49

SBNOV.indd 49 10/15/12 10:31 AM Q: What are the opportunities in the grand-format textile printing market? A: According to a recent study by InfoTrends, printed textiles represents a $165 billion market, and demand is increasing for custom and personalized fabric design for home and office, retail soft signage, trade show and exhibition graphics. While the potential is great, less than 1 percent of printed textiles are digitally printed today, according InfoTrends. These are all areas of opportunity. Another very important point is that the digital textile market is not yet commoditized. Printed fabric still com-

Typical applications for dye-sub include Fabric has a high perceived value that is mands high margins, and the market is flags and banners, stretch graphics, trade opening many doors into a higher-end appli- not saturated. Competing profitably in show graphics, and retail point of purchase. cations and clientele. (Image courtesy of this industry is typically achieved in sev- (Image courtesy of Flag Crafters) Mimaki USA) eral ways:

DIGITAL PRINTING AND FINISHING DIGITAL GRAPHICS AND FINISHING DIGITAL PRINTING DIGITAL • decreasing operating costs on equipment and supplies; • increasing efficiency with automa- tion, or faster equipment; and • finding areas to grow that aren’t yet saturated. Of the approximately 30,000 U.S. sign shops, we estimate that less than 100 are doing industrial grand-format textile printing (we define industrial as 126" or wider on commercial speed inkjet textile printers). According to a recent 2012 SGIA Market Trends report, graphics and It is important for print service providers to understand all of the aspects of the textile printing process—from prepress to production to finishing—to ensure a solid product. sign companies expect a median growth rate of 11.2 percent this year. Of these companies, 60 percent said they will add imaging equipment or technology to their business and 50 percent said they will add post-print or finishing equipment. That trend shows an increasingly crowded market.

Q: What are the primary markets for dye sublimation? A: The soft signage, retail, exhibition graphics, event/entertainment industries and customized fabric are the greatest textile printing opportunities. Typical applications include banners and flags, stretch graphics, trade show graphics, retail point of purchase, and the small niche markets like gaming tables and The best choice is to find the piece of printing equipment that will allow you to do direct print and ceramics. Garments and interior and transfer processes equally well. The Evo 33 pictured is designed to print using both methods. exterior design are also growing markets.

50 • November 2012 • SIGN & DIGITAL GRAPHICS

SBNOV.indd 50 10/15/12 10:38 AM Printed textiles represents a $165 billion market, and demand is increasing for custom and personalized fabric design.

Q: What are the practical challenges perceived value which is opening many Q: When does it make sense to move of entering each market? doors into a higher-end clientele and from outsourcing to in-house dye-sub A: Many of the challenges for enter- enabling printing businesses to increase production? ing these markets are similar. As textile their margins and market share. A: This is really an individual business printing is still very much a craft, cer- Transportation, handling, drayage decision based on market demand, inter- tain aspects need to be considered before and overall fabric management are less nal talent, growth goals and competition. jumping headfirst into this market space. costly as well. In many conventional sig- However, the more expertise PSPs can For example, when fabric is sublimated nage markets, the cost of shipping and develop in the applications and services to, there will be some amount of fabric drayage can far exceed the cost of the they offer, the more successful they will shrinkage due to the high temperatures original graphics. be. This is a way to differentiate their in the sublimation process. It is impor- Textile printing has seen growth in business and remain competitive. tant to recognize this before printing Europe for many years. We are only If a PSP is currently outsourcing as graphics so sizing can be appropriately starting to feel the upswing in demand a start point for their sales and market- adjusted in the RIP software. It is also and know-how here in the U.S. As men- ing efforts, it is a good rule of thumb to important to note that the different char- tioned before, this is not yet a commod- say that when your monthly equipment acteristics of the many fabric options on ity, so margins remain high. The wide- lease rate is close to or more than what the market need to be considered. For format industry in particular is on the you’re outsourcing, it is time to bring it example the many variations of knits leading edge of textile printing—with in-house. This model may help explain and weaves may have different stretch faster machines, improved ink technolo- how to approach the decision. attributes to them, as well as shrinkage gies, printhead development, high pro- rates. Part of the craft is mastering your ductivity and quality output. materials and equipment so that you can go into true production. Specific markets have their own challenges that providers need to be aware of as well. If for example, if a company is planning to get into the tension or stretch fabrics segment of textile printing, it is Buying New important to realize that there are many other things to contend with beyond the print. Many of the structures and graphics in this market space are three dimen- Equipment? sional by nature. A provider may need to source fabrication for the graphic frames (if they are not already doing fabrication Contact Global Imaging. in-house). Additionally, graphics need to be designed and printed with the three Leading U.S. Distributor for dimensional aspect in mind. This may require having someone with CAD expe- Wide Format Equipment, rience on hand to ensure graphics are set Supplies and Technical Services. up properly for this sort of application. In all cases, it is important for the print service provider (PSP) to under- www.globalimaginginc.com stand all of the aspects of the process— 800.787.9801 from prepress to production to finishing —to ensure a solid product.

Q: What are the driving forces for digital textile growth? A: Profitability and demand for a better end product are key drivers as digi- Our Brands • Everything You Need for Wide and Grand Format Success tal imagery and printer output quality continue to improve. Fabric has a high Use Info # 161

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SBNOV.indd 51 10/15/12 3:41 PM Q: What are some industry trends? can be streamlined and production Is direct print sublimation gaining on increased. transfer? An increasing number of printer A: Whether it’s direct print or trans- manufacturers are introducing new fer, dye sublimation is the preferred flatbed and inkjet systems designed for imaging method for soft and retail sig- textile printing which contributes to nage and exhibition graphics because market growth and innovation. As ink of the rich color saturation and consis- and substrate technologies continue to tent high quality results that are pos- advance, the experimentation of differ- sible. Although direct print seems to be ent applications in digital printing will increasing in use and popularity, however expand market demand and increase in my opinion transfer printing is still the competition for unique, creative prod- optimal way to achieve the sharpest, most ucts. According to SGIA’s Marketplace superior end product. The best choice is study, the industry is on an upturn, and to find the piece of equipment that will 88 percent of the study respondents are allow you to do direct and transfer pro- optimistic about the future. Digital imag- cesses equally well. ing is the technology of choice and will Textile customization, especially for eventually replace analogue systems and shorter runs, is a rising trend, and here textiles are poised to replace vinyl and digital printing can save time and money. other rigid substrates. SDG With new specialty inks and improved equipment technologies, the workflow

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52 • November 2012 • SIGN & DIGITAL GRAPHICS

SBNOV.indd 52 10/15/12 10:40 AM Analyzing Dye-Sub ROI This break-even point graphic (provided by Global Imaging) is a tool that is used to evaluate return on investment (ROI) of dye-sub systems by examining many variables including monthly equipment payment, employee cost, monthly rent and other administrative expenses as fixed costs per month with sales and marketing as variable costs. These are for the first year of operation in a five-year lease. The printer considered in this example is a PrinterEvolution Evo33 dye sublimation printer (the “complete” cost listed includes a Caldera RIP, Klieverik calendar press and training). The assumed average sell price per square foot is $6.13. Nationally it seems to vary from $3 to $20 per square foot depending on location, competition etc. Printer capacity is about 112,839 sell- able square feet per month, operating seven hours per day, 22 days per month at 916 average square feet per hour. Selling Used This analysis shows that breakeven is achieved as production reaches approximately 2 percent of machine capacity. Gross margins in the 50 percent range Equipment? are achieved at approximately 4 percent of machine capacity, and are maintained well above that level at all higher pro- Contact Global Garage. duction levels. Total system payoff is achieved in 23.6 months, if maintaining a 100 percent run rate through that period. The worldwide marketplace for Breakeven production is achieved in 0.3 buying and selling used grand days. These are realistically developed format equipment. estimates, however as with all estimates, your return may vary. www.globalgarage.net 800.787.9802

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