PLASTISOL HEAT TRANSFERS

Plastisol heat transfers is the King of heat transfer process. They are used in the apparel industry to apply designs, graphics, or text onto various fabrics. These transfers utilize plastisol ink, which is a particular kind of ink used in screen printing that does not dry at room temperature but instead requires heat to cure and solidify. Plastisol ink is popular due to its durability, color vibrancy, and ease of use. It is the industry standard for fabric screen printing, particularly for heat transfers, due to its unique properties and benefits.

Here’s how plastisol heat transfers work and why they’re popular:

1. Design Creation: The first step involves creating a digital design in a graphic design software like Adobe Illustrator, CorelDRAW, or a similar vector-based program. Vector graphics are preferred for their scalability and clean edges. This design can include logos, text, graphics, or any other imagery that is intended to be transferred onto the substrate.
Design Considerations: Keep in mind the end use of the product. Factors like the fabric type, color, and intended use of the item can influence design elements like color choices and complexity.

2. Ink Preparation: Creating plastisol heat transfers involves preparing a special type of ink used in heat transfer printing on fabrics. Plastisol ink is made primarily of PVC (polyvinyl chloride) resin. It forms a plastic-like layer on the surface of the fabric, which is ideal for durability and vibrant color. It doesn’t air dry; it needs to be heat-cured. Typically, plastisol ink cures at around 160°C, at which point it transforms from a liquid to a solid. Provides excellent coverage, high opacity making it suitable for dark fabrics, also works well on almost all types of fabrics and is excellent for layering colors.

3. Printing on Transfer Carrier: The design is then printed with the screen printing technique onto a special heat transfer paper or directly onto a special clear polyester film using the plastisol inks. This can be done by using solid colors for simple designs or gradients for more complex designs depending on the desired effect.

4. Color Layering: For each of the colors included in the design, a separate screen is prepared. Each screen allows the ink of the specific color to pass through and be transferred to the substrate, which is the transfer paper or a special clear polyester film. The inks are applied in layers, starting with the darkest color and ending with the lightest. The registration of these colors in varying patterns recreates the complex colors and details of the original image.

5. White Layering: In specific cases when the printing of the colors is completed, white ink is printed behind the entire design as a base for two main reasons. One reason is to add extra elasticity to the design, and the second is to provide the brightness needed for the design on dark fabrics.

6. Heat transfer adhesive Layering: In specific cases of temperature-sensitive or difficult, rough and hard fabrics, an additional process may be required, during which a layer of heat transfer adhesive in powder form is added at the bottom of the transfer for better adhesion to the fabric.

7. Curing the Ink and the adhesive: After printing, the ink and the adhesive on the carrier (paper or film) are partially cured (or gelled) using a heat source e.g., an oven, but not fully solidified. This step is crucial because it ensures that both the ink and the adhesive will fully transfer and adhere to the fabric during the heat press process. As a result, this technique guarantees that the plastisol inks form a durable, long-lasting finish on the fabric.

8. Heat Transfer Process: After the design is screen printed onto the carrier (paper or film) and it has dried and fixed in the oven, is then placed adhesive-side down on the garment and pressed using a heat press. The press applies heat and pressure, which causes the activation of the adhesive bonding the design to the fabric. This method allows for the detailed and vibrant designs characteristic of screen printing to be transferred efficiently onto the fabric. The temperature, time and pressure settings are critical and vary based on the fabric type and the specific ink used.

9. Peeling Off the Carrier: After the heat transfer application, the carrier (paper or film) is peeled away while hot or cold (depending on the type of transfer carrier and ink used), leaving the design permanently embedded on the fabric.
10. Final Appearance: The final appearance of plastisol heat transfers on fabric is notable for its vibrant colors and sharp, clean edges, making it highly desirable for various applications in the fashion and promotional industries. The design is also durable and able to withstand washing and wear.

Visual Appeal and Functional Benefits:

Aesthetic Versatility: Plastisol heat transfers can be used to achieve a wide range of graphic styles, from simple text and logos to complex, multi-colored designs. This versatility makes it popular for both artistic and commercial projects.

Consistency: Each transfer maintains consistent quality, which is crucial for producing multiple items with the same design, such as uniforms or retail merchandise.

Customization: Offers excellent customization options, enabling unique designs and limited-edition runs that are appealing in modern apparel markets.