Decoration#4 Transfers

Wednesday, 30 November 2011

Hi Guys,

Today we are continuing our run of decoration technique information for you, so that you get a feel for what is happening behind the scenes and so you can also understand where your costs are coming from.

What is a Transfer?

Digital:
Digital transfers are a common technique used on a number of items including bags, headwear, clothing and apparel.
Essentially using a wide format inkjet printer an image is produced onto a substrate (paper products) which is then heat pressed to the item. By using this technique you can achieve full colour photographic quality with CMYK graphics produced at 300dpi.

Plastisol:
A plastisol transfer has the same use as a digital transfer, however instead of using an inkjet printer to create it, your image is screen printed onto the substrate and then applied via the heat press to the item. Plastisol transfers provide the highest quality and longevity of the transfer methods available, as the screen printing puts down a heavier layer of ink than that of the digital version.

It is worth noting that you cannot produce high quality photo images with this process, such as you can with the digital alternative. It is however exceptional at producing spot colour company logo’s.

What determines the cost of transfer printing?

Digital:
The cost is simply the cost of ink charges, substrate and labor. For digital transfers there are no set up charges, as the output is direct from computer to the transfer sheet. So the cost of the printing is really quite cheap. The additional costs that you get are from the labor involved in applying the transfer to the promotional product to get your end result.

So given that there are no set up charges applicable to this process, it is perfect for short run garment orders that can become extremely expensive via direct screen printing that require film and screens to be produced.

Plastisol:
The costs of plastisol transfers incorporate all of the associated costs listed for digital. They do have the additional cost of producing screens, such as the screen printing process, and thus do not have the flexibility for short run orders.

It is worth noting though, that you can have transfers printed and held in stock for up to 12 months. This can be a great way to maximize your investment and economies of scale. Produce 100 transfers and use half now on your T Shirt requirements with the balance held in stock.

Come back in six months and do another run and you won’t have to pay for those set up charges again as the print has already been done!

The transfer process.

1.    Footprint provides the decorator artwork:
A)    Digital: PDF high resolution file with artwork at 300dpi to size.
B)    Plastisol: EPS Vector art file.
2.    Transfers are created:
A)    Digital: Inkjet printer outputs to transfer sheet.
B)    Plastisol: Screen printing process outputs to transfer sheet. (See screen printing process)
3.    Transfers are then applied to the item and using a heat press (temperature, pressure and time controlled) the ink from the transfer sheet adheres to your promotional item.
4.    Transfer sheet is removed from the product and your item is complete.

Here is a really quick clip that shows the process: CLICK HERE

This one’s a little more hardcore, done before the garment is produced on a much larger scale. CLICK HERE

Until next time, take it easy…

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Decoration Techniques