Sublimation vs. Simulated: What’s the Difference?

Hey Bulkthreads family, 

When it comes to creating high-quality, full-color designs on t-shirts, two of the most popular methods are sublimation printing and simulated process screen printing. While both can achieve stunning results, they’re fundamentally different in materials, technique, and outcome. Here’s a clear breakdown to help you choose the best method for your next project. As teenagers often say, don't worry--we got you. 

Sublimation

Sublimation printing uses heat to transfer a specially formulated dye directly into the fibers of polyester fabric (if using soft materials, like tees) or onto hard products via surface pores. In the sublimation process the ink turns into a gas under heat and bonds permanently with the fabric, which creates what so many sublimation lovers want out of their printing: a vibrant, long-lasting image you can't feel because it's pressed into the fabric. 

One key note: to sublimate apparel, you also need special film, adding to your costs and the time required to complete your job.   

Want to know more about the science of sublimation? Read this. 

Awesome for:

• 100% polyester or high-polyester blends, as well as hard goods (think open pores)
  
• All-over prints or prints that need a photorealistic design

People love it because:

• No ink texture – the design becomes part of the shirt
• Bright, vivid colors
• Durable and fade-resistant

People don't like it because:

• Doesn't work with 100% cotton
• Can be expensive and time-consuming for complex designs, which means it also may not be the best option for large orders (say, 100 or more prints). Once set up is done for traditional screens, printing is a breeze. With sublimation, every shirt needs a film and a heat press--that takes time (and patience). 

So what's simulated screen printing?

Simulated screen printing is a specialized screen printing method that uses halftone techniques to simulate full-color images with a limited ink palette (often CMYK + spot colors). It’s ideal for printing highly detailed or more photorealistic designs on apparel. 

Awesome for:

• Speeding up your print timesif you're curing multiple types of apparel. 
• Capturing lots and lots of detail
• Vivid colors
• Flexible printing--you can use it on pretty much any color out there!

People like it because:

• Works on every color,light or dark or in-between
• It's great for large production runs
• It produces soft, vintage-style prints with proper setup. What printers call "soft hand." Essentially, it doesn't leave a thick, sticky print on your super soft, ringspun tee

People don't like it because:

• Setup is more complex (multiple screens, color separations)
• Can be more expensive than traditional printing
• Can struggle with sharp text

We hope the above helps, but as they say, seeing is believing, so here's a quick visual representation. As always, the brightness of your screen and your computer settings might make the image look a little different to you than to others, so no mockup is ever going to be perfect--but the following should give you some idea of how sublimation and simulation differ.  

Side-by-side visual comparison

• Left: Sublimation – Typically, sublimation will be a bit more vibrant, a bit more smooth with its gradients, and will print into the shirt (in this case, a bag) for a complete bonded feel and look. (Hence the smoothness.)

• Right: Simulated – Since the simulated process prints onto the shirt, you'll have a bit more texture and a bit less vibrance. 

Final comparison table

So which one should you choose?

Choose sublimation if you're printing full-color designs on high polyester shirts, want maximum vibrancy, and a super-soft finish. Go with simulated process if you're working with cotton garments and need realistic or detailed multi-color prints.

Need help choosing the right print method for your business or brand? Reach out—we’d be happy to guide you!