10 Common Problems in Sublimation with Polycrylic and Solutions

Polycrylic can be an effective coating for sublimation on non-polyester surfaces. However, the process has specific challenges that can affect print quality and durability. This guide outlines the most frequent issues and offers practical solutions.

1. Uneven Coating Application

Problem:
Brush strokes, drips, or inconsistent layers lead to patchy color transfer.

Solution:

• Use a high-quality foam brush or spray application.
• Apply multiple thin coats instead of one thick layer.
• Sand lightly with fine-grit sandpaper between coats for a smooth surface.

2. Streaks or Lines in the Print

Problem:
Visible lines appear after pressing, often due to brush marks in the Polycrylic layer.

Solution:

• Let each coat self-level before drying.
• Avoid over-brushing once the layer starts to set.
• Consider spraying for a more even finish.

3. Yellowing After Heat Press

Problem:
High heat can cause the Polycrylic to discolor.

Solution:

• Keep pressing temperatures within 385°F–400°F (196°C–204°C).
• Reduce pressing time when possible.
• Allow the coated surface to cure fully for at least 24–48 hours before pressing.

4. Blurry or Faded Image

Problem:
Design lacks sharpness, usually caused by surface texture or insufficient curing.

Solution:

• Ensure the coated surface is smooth and fully cured.
• Increase pressure slightly for better ink penetration.
• Check sublimation paper for compatibility with hard surfaces.

5. Ghosting or Double Images

Problem:
Image shifts slightly during pressing, creating a blurred outline.

Solution:

• Secure sublimation paper with heat-resistant tape.
• Avoid moving the press before the substrate cools slightly.
• Apply even pressure throughout the press.

6. Peeling or Flaking of Design

Problem:
Sublimated design lifts or chips over time.

Solution:

• Ensure the Polycrylic layer is fully cured before pressing.
• Avoid thick or uneven coating layers.
• Handle the finished product gently for the first 24 hours.

7. Poor Ink Absorption

Problem:
Colors appear dull because the coating doesn’t bond well with the ink.

Solution:

• Stir the Polycrylic before use to avoid ingredient separation.
• Apply at least two coats for proper coverage.
• Press with firm pressure to help ink embed in the coating.

8. Bubbles or Texture in the Coating

Problem:
Air bubbles create an uneven surface, disrupting image transfer.

Solution:

• Apply the coating slowly to avoid air entrapment.
• Use a foam brush and smooth strokes.
• Let each layer dry completely before adding the next.

9. Warping of the Substrate

Problem:
High heat causes non-heat-resistant surfaces to bend or warp.

Solution:

• Choose substrates rated for heat press use.
• Use a lower temperature with a slightly longer pressing time if needed.
• Support thin substrates with a flat backing during pressing.

10. Surface Contamination

Problem:
Dust, fingerprints, or residue prevent the ink from bonding.

Solution:

• Clean the surface with isopropyl alcohol before coating.
• Store coated items in a dust-free environment until pressing.
• Wear gloves to avoid skin oils transferring.

For a step-by-step coating method and temperature guide, see How to Use Polycrylic for Sublimation.

Quick Reference Table

Issue	Likely Cause	Best Fix
Uneven coating	Thick layers, poor tools	Thin coats, foam brush, sanding
Streaks/lines	Over-brushing, uneven leveling	Let self-level, spray application
Yellowing	Excessive heat/time	Lower temp/time, cure fully
Blurry/faded image	Surface texture, uncured coating	Smooth surface, increase pressure
Ghosting	Paper movement	Tape, steady pressing
Peeling/flaking	Thick coats, uncured layer	Thin coats, full cure
Poor ink absorption	Thin coating, low bonding	Two coats, firm pressure
Bubbles/texture	Air in application	Slow strokes, full drying
Warping	Low heat resistance	Lower temp, support backing
Contamination	Dust, oils, residue	Clean with alcohol, use gloves

Common Mistakes to Avoid

• Applying thick coats – Leads to uneven curing and poor ink absorption. Always use thin, even layers.
• Not letting the coating cure fully – Pressing too soon can cause peeling, bubbling, or faded prints.
• Skipping surface preparation – Dust, fingerprints, or oils block ink bonding. Clean with isopropyl alcohol first.
• Using excessive heat or time – Can cause yellowing or warping. Stay within recommended press settings.
• Over-brushing during application – Creates streaks and visible lines in the final print.
• Ignoring humidity levels – Moisture slows curing and can trap bubbles. Work in a dry, ventilated area.
• Failing to secure transfer paper – Movement during pressing causes ghosting or double images.
• Pressing on low heat-resistant surfaces – Can lead to deformation or damage to the blank.
• Not sanding between coats – Skipping this step leaves surface texture that affects image clarity.
• Storing coated items in dusty spaces – Dust settles on the surface and shows through the final design.