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Heat transfer vinyl (HTV)

Another form of T-shirt decoration is heat transfer vinyl, also called HTV. HTV is a polyurethane material that allows apparel designers to create unique layered designs using a specialized software program. Once the design is created, it is then cut through the material using a vinyl cutter (or Cut n Press) machine.

There are dozens of different colors available, as well as glitter, reflective, and now even unique patterns (such as mermaid skin) which come in rolls and sheets.

After the design is cut, there is a process called “weeding” whereby the areas of the design that do not represent the design are picked away from the transfer sheet and removed so that the intended design remains. HTV is typically smooth to the touch and does not feel rubbery or stiff. The edges are typically clean cut and produce high contrast.

Designers can also create multiple color designs, or multi-layered designs using HTV. This process would be done in the design software before the design is sent to the cutter for the different materials. A heat press is then used to apply pressure and heat to the vinyl so that the material permanently adheres to the garment. The temperature and pressure vary according to the manufacturers specifications.

 

T-shirt day in Leipzig, Germany

Dye-sublimation printing

Dye-sublimation printing is a direct-to-garment digital printing technology using full color artwork to transfer images to polyester and polymer-coated substrate based T-shirts. Dye-sublimation (also commonly referred to as all-over printing) came into widespread use in the 21st century, enabling some designs previously impossible. Printing with unlimited colors using large CMYK printers with special paper and ink is possible, unlike screen printing which requires screens for each color of the design. All-over print T-shirts have solved the problem with color fading and the vibrancy is higher than most standard printing methods but requires synthetic fabrics for the ink to take hold. The key feature of dye-sublimated clothing is that the design is not printed on top of the garment, but permanently dyed into the threads of the shirt, ensuring that it will never fade.

Dye-sublimation is economically viable for small-quantity printing; the unit cost is similar for short or long production runs. Screen printing has higher setup costs, requiring large numbers to be produced to be cost-effective, and the unit cost is higher.