What is Dye Sublimation?
What is Dye Sublimation?
Dye sublimation, or digital sublimation, is a revolutionary digital printing technology that utilizes heat and specialized paper or polyester film to transfer a printed pattern or unique image onto a final product. While this process can be used for fabric, it is most frequently used to apply wood grain patterns and other natural material patterns onto aluminum or steel components used in architectural, construction, furniture, and appliance manufacturing applications. Advanced Finishing USA, with the help of Decoral System’s® modernized technology, has become an industry-leading provider of wood grain dye sublimation services for countless industries. This article will answer the all-important question of what is dye sublimation, the benefits of using this process to replicate natural materials, and some common applications where dye sublimation has become the leading finishing practice.
How Does Dye Sublimation Work?
The process of dye sublimation for aluminum or steel components was first developed in 1993 by Decoral Systems® and quickly spread to officially licensed metal finishing companies across the globe. Advanced Finishing USA is one of the single largest independent licensees in the United States and uses the process explained below to replicate the incredible hues, warmth, and detailed patterns of real wood and other materials.
Step One: Choosing A Metal Substrate
As previously mentioned, dye sublimation is predominately used on fabric or cloth, but is more commonly used by metal finishing providers on components made from aluminum or steel, and even MDF. There is only one limiting factor that determines material viability for dye sublimation, that being temperature resistance. The dye sublimation process requires temperatures of up to 392℉ (200℃) to adequately transfer the ink from the printed film to the intended surface.
Step Two: Pre-Treatment
Pre-treatment is critical for any metal component undergoing supplemental finishing techniques and this is no different for dye sublimation. The component or part should be thoroughly cleaned and free of any debris that could interfere with the subsequent steps. The clean part then must have a pretreatment that will render the surface relatively inert to oxidation. This is essential for protecting the metal surface from eventual corrosion or adverse reactions to environmental conditions like UV, rain, or salt spray.
Step Three: Base Layer Powder Coating
The pattern created through dye sublimation does not adhere directly to the metal substrate and these parts must first be uniformly powder-coated to provide optimal results. In this stage, electrically charged thermoset polymer particles are sprayed onto the metal surface and then cured in an oven. This durable base layer of powder coating provides the necessary protection from corrosion, weathering, or abrasion present in certain applications.
Step Four: Dye Sublimation
Now that the metal component has been thoroughly cleaned and powder coated, it is finally ready to receive the designated wood grain or other pattern through dye sublimation. A digitally printed heat-transfer film is wrapped along the product to match design requirements and then vacuum sealed to remove air bubbles that may impact the final appearance. Once sealed, the part is placed in an oven that utilizes both heat and pressure to transfer the ink into the powder coat layer. Once fully sublimated, the film layer is removed and leaves behind an attractive and durable finish.
Benefits of Using Dye Sublimation
With most of the industrial world receiving pressure to shift towards more sustainable products and finishing techniques, dye sublimation has quickly risen to the top of optimal procedures with several benefits.
- Environmentally Sustainable: Rather than utilize naturally occurring hardwoods and contribute to deforestation, industries are switching to dye-sublimated aluminum. Additionally, this process does not require any volatile organic compounds (VOCs) or additional toxic chemicals that can be challenging to apply and properly dispose of.
- Granite and Rare Natural Stone Patterns: The price of granite is dependent on its availability. As certain patterns are used up, the price for the remaining stone increases proportionally. The dye sublimation process can not only offer an unlimited supply of faux granite and stone but can also reduce the demand for a finite amount of valuable natural resources. The finished products can be used for interior and exterior applications.
- Improved Durability & Resistances: With a uniform powder coating base layer beneath the decorative pattern, dye-sublimated aluminum products are exceptionally durable and offer impressive resistance levels to adverse weather conditions and UV exposure in external applications. The polyurethane base powder is also incredibly durable, which is why polyurethane is used on most wood floors.
- Reduced Maintenance & Replacement Frequency: Thanks to the durability and weather resistance mentioned above, these products require minimal maintenance and can outlast natural wood alternatives considerably. For internal aluminum components or parts, the surface can be quickly cleaned or sanitized using simple soap solutions. Any harsh chemicals or solvents should be avoided as they can damage the coating. The coatings can also be formulated with silver ion antimicrobial additives to promote health safety.
- Efficient Costs to Consumers: From lower initial costs for base materials to avoiding natural alternatives and reduced replacement frequency, dye sublimation is an efficient process that can reduce overall costs to consumers, especially on large-scale commercial infrastructure or manufacturing projects. Formed aluminum is also lighter and easier to work with and install than natural wood.
What is Dye Sublimation Best Suited For?
The beauty of dye sublimation is that few if anyone, could differentiate the difference between coated aluminum or steel from natural wood alternatives. This impressive replication of unique wood grain or stone patterns immediately made dye sublimation a highly desirable finishing process for countless industries. Not only does it replace expensive and less durable natural materials, it allows designers, architects, and manufacturers to expand their design capabilities and match evolving customer demands. Common applications for this process include appliance manufacturing, exterior building facades, decorative panels, interior/exterior hand railings, curtain walls, and replacing natural wood in various door or window trims for commercial and residential applications.
Some examples of the wood grain patterns Advanced Finishing can replicate through dye sublimation are displayed below. Please contact our team for a more comprehensive offering list or inquire about a pattern not shown here.
Cherry Flame
Douglas Fir
Golden Oak
Cherry Flame
Knotty Pine
Douglas Fir
Narrow Oak
Antique Oak
Light Maple
Chestnut
Teak
Dark Walnut
Antique Oak
Working with Advanced Finishing USA
Advanced Finishing USA is one the largest and most experienced dye sublimation companies utilizing the revolutionary Decoral Systems® technology and application process. With over fifty years of experience working with countless industries, the team at Advanced Finishing can reproduce varying natural wood grain or stone patterns onto steel or aluminum components that outlast and outperform even in the most challenging conditions. If you have an upcoming specialty or production-run project that requires dye sublimation or simply would like to learn more about how this process can help you grow and expand your product offerings, contact a member of our team today!