In an example implementation, an image transfer method includes inkjet printing a latex ink image onto a propylene-ethylene copolymer film extruded onto a single-layer image transfer sheet. The method includes putting the latex ink image and the single-layer image transfer sheet in contact with a substrate, and using heat and pressure to exclusively transfer the latex ink image onto the substrate, after which the single-layer transfer sheet is removed from the substrate.

A process for printing on to a 3-dimensional article is described. An image is printed on to a first side of a stretchable carrier membrane having a first side and a second side. The membrane is mounted in a plane within a frame between a heating chamber defined on one side of the membrane, and an article receiving chamber defined on the other side of the membrane. A 3-dimensional article to be printed is placed on to a generally flat platen positioned generally parallel to the said plane, optionally with a nest for the article thereon, within the article receiving chamber. A thermo- and vacuum-forming step is performed in which there is relative movement of the platen with respect to the membrane in a direction perpendicularly to the said plane to bring the article into register with the image printed on the membrane and to carry the article into intimate contact with the membrane through the said plane into the heating chamber. A source of vacuum is applied to the membrane from the said other side, and heat is applied to the membrane from the said one side at a first temperature sufficient to soften the membrane, whereby the membrane is thermo- and vacuum-wrapped at least partially about the article with the membrane in intimate contact with surface details of the article. A dye-diffusion step is performed in which infra-red radiation is applied to the article with the membrane wrapped therearound using at least two infra-red sources to heat the membrane and underlying surface of the article over substantially a half-spherical solid angle uniformly to a temperature in excess of the first temperature and for a time sufficient to cause the printed image to diffuse into the surface of the article but insufficient to damage the article.

A two-part method for dye-sublimation printing a decorative design on a moldable orthotic substrate comprising a first digital printing step of printing a computer image file of a decorative design on a digital transfer paper substrate using dye-sublimation CMYK inks, and a second dye-sublimation printing step comprising the steps of heating an oven to a first temperature, placing a moldable orthotic substrate inside the oven, heating the moldable orthotic substrate to a second temperature, positioning the digital transfer paper substrate on the moldable orthotic substrate with the decorative design down and in contact with the moldable orthotic substrate, and sublimating the at least one color of dye-sublimation CMYK inks from the digital transfer paper substrate to the moldable orthotic substrate. A custom orthotic product may be manufactured by wrapping the dye-sublimation printed moldable orthotic substrate around an orthotic mold and applying a vacuum.

Various of the disclosed embodiments concern printing systems configured to deposit flexible dye sublimation inks onto flexible transfer materials. Together, the flexible ink and transfer material allow images to be transferred onto complex-shaped, i.e. non-planar, surfaces of a substrate. The flexible ink may be, for example, a thermoformable UV dye sublimation ink or a superflexible UV dye sublimation ink. In order to transfer an image onto the substrate, the transfer material is pressed onto the surface of the substrate. The substrate, transfer material, or both are heated to a temperature sufficient to cause the ink to sublimate. During the sublimation process, dye is able to permeate the substrate and form a transferred image. The flexible ink formulation may also include a soluble or solvent-sensitive component. In such embodiments, a solvent can be jetted onto the substrate and/or transfer material to remove residual ink.

A sublimation transfer sheet including a backing layer positionable between overlapping end portions of the sublimation transfer sheet, method of using the same, and object decorated with method of using the same. Preferably, the backing layer is an absorbent layer. Also preferably, the backing layer is secured to a side of a release layer facing away from a side of the release layer having dyes or inks thereon.

Aspects are directed to printing a garment and include a method having steps of providing a fabric panel containing polyester, applying an ink layer to a first area of the fabric panel, curing the ink layer, and applying a sublimation dye to the first area and a different second area of the fabric panel. Application of the sublimation dye causes the first area and the second area to have different color saturations. Other aspects include a garment with a fabric panel containing polyester that has a first surface with a first area and a different second area. The garment also includes an ink layer on the first surface and located at the first area and a sublimation dye absorbed by a portion of the fabric panel at the second area and on a surface of the ink layer at the first area.

Methods and apparatus for sublimation printing are described, in which a printed textile medium with a sublimating printing substance on a print side is positioned in correspondence with a heating device, with the print side facing away from the heating device, and a negative pressure is caused on the print side of the textile medium, to cause heated air to flow through the printed textile medium thereby sublimating the sublimating printing substance on the printed textile medium.

A process and apparatus for sublimating printed images onto two or more sides of a product simultaneously using a single heating platen are disclosed. The apparatus is configured to print one or more images onto transfer media, then position the transfer media onto a substrate. A product to receive the sublimated image is positioned on top of the transfer media, and the apparatus manipulates the transfer media to substantially surround the product and place at least one image onto each side of the product to be sublimated. A single heating platen then engages the transfer media to sublimate the image. The heating platen is configured, using a control, to sublimate opposing sides of a product substantially simultaneously in a single thermal cycle.

A dye sublimation apparatus is disclosed. The apparatus is configured to either print one or more images onto transfer media, or to print images directly onto products. A selected product to receive the image(s) is positioned on a platen configured to receive one or more types of such products into channels matching those products' dimensions. Proper positioning of the transfer media (or the product, when directly printed) is facilitated by aligning fiducial markers printed on the transfer media and/or product with one or more lights disposed on the platen. The apparatus comprises one or more heating platens configured to sublimate one or more sides of the product in a single thermal cycle with a predetermined temperature, pressure, and duration based on properties of the product. The product platen is translated inside and out of the apparatus by a reversible motor.

Retransfer printing methods and systems are described where a variable stripping process is utilized while stripping all or a portion of the retransfer film (also known as intermediate transfer media) from the surface of a substrate. The variable stripping process includes stripping the retransfer film from different sections of the substrate surface while applying different tensions to the retransfer film and/or at different transport speeds of the retransfer film and the substrate.