Polyester Sublimation Guide: Blends, Techniques & Best Blanks
Why polyester is ideal for sublimation
Polyester bonds with sublimation dye at a molecular level when heated.
This creates vibrant, permanent prints that won’t crack, peel, or fade.
Natural fibers like cotton don’t allow dye to embed deeply.
Polyester’s synthetic structure makes it the best surface for dye infusion.
What Polyester Blend Works Best?
- 100% Polyester: Best for bold, full-color designs
- 65/35 Poly-Cotton: Breathable with solid color retention
- 40% Polyester: Faded, vintage look only
✅ Use blends with at least 65% polyester for long-lasting results.
Why Do Some Shirts Bleach Unevenly?
Low-polyester fabrics absorb heat and chemicals inconsistently.
Polyester ensures even bleaching and smooth dye transfer.
How Does Polyester Improve Sublimation Quality?
- Dye Bonding: Synthetic fibers trap ink permanently
- Heat Resistance: Withstands up to 400°F without damage
- Versatility: Works across garments, mugs, totes, and more
- Cost-Effective: Polyester blanks are 20–30% cheaper than cotton
Quick Tips for Better Results
| Blend Type | Best For | Pro Tip |
|---|---|---|
| 100% Polyester | Full-color prints | Press at 385–400°F for 45–60 seconds |
| 65/35 Poly-Cotton | Breathable shirts | Apply polyester spray to boost color |
| 40% Polyester | Washed-out, vintage | Use lower heat (360°F) to avoid scorching |
Can You Sublimate on Dark Polyester?
Yes, use high heat and high-contrast designs.
Dark fabrics may need a white base layer or glitter vinyl.
Check more about Polyester Hoodie for Sublimation
What Polyester Percentage Works Best for Sublimation?
Higher polyester means better dye bonding.
Lower polyester blends may cause faded or uneven prints.
How Does Polyester Content Affect Sublimation?
| Blend Type | Dye Retention | Best For |
|---|---|---|
| 100% Polyester | 95–98% | Sportswear, banners, mugs |
| 65/35 Poly-Cotton | 75–85% | Everyday tees, tote bags |
| 40% Polyester | 50–60% | Vintage-look, distressed wear |
Why Choose 100% Polyester?
- Opens under high heat (385–400°F)
- Dye bonds at a molecular level
- Wash-safe for 50+ cycles
- Best for sharp, all-over prints
⚠️ Tip: Use a Teflon sheet to avoid scorching delicate fabrics.
What Makes 65/35 Blends a Good Choice?
- Combines comfort with color performance
- Use polyester spray (like Poly-Wow) for 40% brighter colors
- Press at 370°F for 50 seconds
⚠️ Overheating scorches cotton. Underheating prevents full dye activation.
Can You Sublimate on Low-Polyester Fabrics?
Yes, but expect faded results without enhancement.
- Good for retro or distressed styles
- Pre-treat with polyester spray to mimic higher poly content
- Lower heat to 360°F to protect cotton
Tips for Polyester Blends
- Dark Colors: Use 100% polyester to prevent ghosting
- 80%+ Blends: No coating needed—save time and money
- Test First: Always press a swatch before full production
Top Products for Sublimation
The right process and the perfect polyester canvas are crucial for sublimation, not just technique. These staples can be used to create gym gear or boutique home décor, and they deliver results that are worth bragging about.
1. Apparel: The Wardrobe Workhorses
- 65/35 Poly-Cotton Tees: The go-to for everyday comfort. Brands like Gildan’s SoftStyle (3–3–5 per blank) balance softness with dye retention.
- 100% Polyester Performance Shirts: Ideal for sports teams or athleisure. Moisture-wicking fibers keep prints crisp through sweat and washes.
- Plus-Size Sweatshirts: Opt for 65% polyester blends (like Hanes’ EcoSmart) to avoid the stiff feel of 100% synthetic fabrics.
- Pro Tip: Pre-treat 50/50 blends with polyester spray to “trick” dyes into adhering like they would on higher-poly fabrics.
| Apparel Type | Ideal Poly % | Avg. Cost |
|---|---|---|
| Graphic Tees | 65–80% | 2.50–2.50–6 |
| Hoodies | 65–100% | 8–8–15 |
| Athletic Jerseys | 100% | 10–10–20 |
2. Bags: Walkin’ Billboards
- Tote Bags: 100% polyester totes (12 oz. canvas) hold bold logos without bleeding. Bulk buys (50+ units) drop costs to 2–2–4 each.
- Reusable Grocery Bags: Lightweight 40% polyester blends work for subtle designs—think farmers’ market branding.
- Pro Tip: Double-stitch handles on sublimated polyester bags; heat pressing can weaken seams over time.
3. Hats: Curve-Ball Creativity
Structured 100% polyester caps (like FlexFit 6533) handle full-wrap designs, while unstructured styles suit vintage looks.
- Avoid: Blends under 60% polyester—dyes fade unevenly on curved surfaces.
- Hack: Use hat presses with magnetic closures for even heat distribution.
4. Home Goods: Beyond the Basics
- Polyester Blankets: 100% microfiber throws (8–8–12) are a hit for personalized gifts. Bonus: They withstand 400°F without warping.
- Decorative Pillows: Opt for 65/35 blends for a linen-like texture that still holds color.
- Pro Tip: For wall art, polyester canvas (180–200 gsm) mimics gallery-grade prints at half the cost.
The Budget Breakdown
- Bulk Blanks: Ordering 100+ units? Tote bags drop to 1.80 each teeshit1.50.
- Amazon Finds: Search “100% polyester sublimation shirts” for budget-friendly options under $4.
- Skip the Middleman: Manufacturers like JINKE offer custom-cut polyester blanks (no minimums).
How Do You Get Perfect Sublimation Results on Polyester?
Success depends on four key factors: coatings, bleaching, heat settings, and post-press care.
When Should You Use Coatings for Sublimation?
Use coatings on:
- Fabrics with under 80% polyester (e.g. 65/35 or 40/60 blends)
- Dark garments that resist dye absorption
✅ How to Apply Polyester Coating:
- Shake well for 30 seconds
- Spray 8–10 inches from fabric in sweeping motions
- Let dry 5–10 minutes—no heat gun needed
| Fabric Type | Coating Needed? | Result Without Coating |
|---|---|---|
| 100% Polyester | ❌ | Bright and vibrant |
| 65/35 Blend | ✅ | Patchy, faded colors |
| 50/50 Black T-Shirt | ✅ | Ghosting, uneven results |
How to Bleach for Sublimation Effects?
Create distressed or vintage looks on synthetic blends.
Steps:
- Mix 1:1 bleach and water
- Apply with spray or sponge
- Stop reaction using 1:10 peroxide-water mix
- Rinse and dry completely before pressing
⚠️ Always test bleach patterns on scraps—spread is unpredictable.
What Are the Best Heat Press Settings?
| Fabric Blend | Temp (°F) | Time (sec) | Pressure |
|---|---|---|---|
| 100% Polyester | 385–400 | 45–60 | Medium |
| 65/35 Poly-Cotton | 370–380 | 50–55 | Medium-Light |
| 40/60 Poly-Cotton | 360 | 30–40 | Light |
| Dark Polyester Shirts | 400 | 60–70 | Firm |
Tips:
- Use Teflon sheets to avoid scorching
- Maintain even pressure to prevent shadow lines
What Should You Do After Pressing?
- Peel hot for glossy finish
- Peel after 10 seconds for matte finish
- Cool flat for 2–3 minutes
- Run a cold wash test to confirm color hold
Troubleshooting Common Sublimation Issues
| Problem | Fix |
|---|---|
| Ghosting on black shirts | Increase temp to 400°F; add 10 sec |
| Cracking ink | Use blends with 80%+ polyester |
| Scorched fabric edges | Lower heat by 15°F; use silicone pad |
Need help with a specific fabric or stubborn blend?
Submit your challenge — and get expert fixes tailored to your setup.
How Do You Sublimate on Dark Polyester?
Dark colors need extra care to avoid ghosting or dull prints.
✅ Fix for Washed-Out Colors on Dark Polyester:
- Use 100% polyester only – blends don’t block background tones
- Set heat to 400°F for 60–70 seconds
- Pre-press for 10 seconds to remove moisture
- Add a drop of black ink to boost contrast on charcoal or navy
Can You Sublimate on Poly-Cotton Blends?
Yes, but prep is essential. Lower polyester means lower dye retention.
65/35 Poly-Cotton:
- Problem: Colors look faded
- Fix: Use polyester spray coating (like Printer’s Jacket) to increase vibrancy by up to 40%
40/60 Poly-Cotton:
- Problem: Prints crack after washing
- Fix: Pretreat with adhesive spray
- Lower press temp to 360°F to reduce cotton stress
Common Blend Issues and Quick Fixes
| Fabric Blend | Issue | Quick Fix |
|---|---|---|
| 50/50 | Fading under arms | Pre-wash to remove sizing |
| 80/20 | Dye bleeding | Skip coating; reduce pressure |
| 100% Poly | Scorching | Use Teflon; cap heat at 385°F |
How to Bleach Polyester Safely for Sublimation?
Create vintage looks without ruining fabric.
Steps:
- Test on scrap—bleach reacts differently on synthetics
- Mix 1:1 bleach and water
- Dab lightly with sponge
- Rinse using 1 cup vinegar + 1 gallon water
⚠️ Don’t over-bleach—excess weakens fibers and distorts shape.
What’s the Best Way to Test Blends Before Sublimation?
Avoid ruining blanks with this $2 method:
- Use fabric scraps from seams
- Practice on misprinted blanks or factory seconds
What If Sublimation Still Fails on Blends or Dark Shirts?
| Problem | Fix |
|---|---|
| Ghosting on darks | Layer two transfers—white underbase + color |
| Dye shedding | Post-press soak in dye fixative (Rit ColorStay) |
Where Can I Buy Bulk Sublimation Blanks?
Buy in bulk from these suppliers for the best prices:
- JiffyShirts: Large selection of polyester blanks at competitive rates
- Sublimation 101: Offers both blanks and accessories, great for beginners
- Blank Apparel: Bulk buying options for t-shirts, hats, and more
Advantages: Lower prices for large orders, quick shipping, and diverse product ranges.
Can I Buy Sublimation Blanks on Amazon?
Yes, Amazon has a wide range of sublimation blanks.
- A sublist of options:
- Aopoker Blank T-Shirts
- TSC Blank Mugs
- Sublimation Blanks Coasters (Jotos)
- Subli Genius Print Sublimation Blank
- Pro tip: Always check ratings and reviews to ensure quality.
What Are the Best Sublimation Blanks to Buy?
Here are some top choices based on material and print quality:
| Product Type | Best For | Recommended Supplier |
|---|---|---|
| 100% Polyester Shirts | Vibrant all-over prints | JiffyShirts, Sublimation 101 |
| Sublimation Mugs | Personalization gifts | Amazon, Joto |
| Polyester Tote Bags | Custom bags and apparel | Blank Apparel |
Stick to 100% polyester for the best results; use higher blends for softer items like tees.
Where to Find the Best Deals on Sublimation Blanks?
- Amazon: Look for sales or bundle deals to save on blanks
- Sublimation Specialty Stores: Bulk deals and discount offers, especially during holidays
Pro tip: Sign up for newsletters for exclusive discounts and bulk purchase promotions.
