Why Sublimation on Mylar Bags Isn’t Always Straightforward

Initially, it seems as though sublimation could be a magical process. You apply ink to something, heat it up, and poof! The ink then becomes part of the media. No cracking, no peeling, no irregular textures. However, once Mylar comes into play, that fantasy gets dashed pretty quickly. A common question is whether or not you can sublimate onto Mylar Bags. The answer to that question doesn’t provide a clear “yes” or “no.” It’s more of a…”sometimes, but only if everything matches up perfectly."

Unlike cotton or coated polyester, which are definitely conducive to sublimation; Mylar is a multi-layered material, typically consisting of plastic film, and sometimes aluminum foil. Each of these layers provides excellent barrier protection, shelf-life extension, and durability; however, they don’t exactly provide hospitable conditions for sublimation. The ink being used must have a polyester coating on which to bond properly, and most Mylar Bags do not have such a coating.

Matte Mylar Bags yield more interesting results as their uncoated surfaces are slightly better suited for receiving sublimated images than those of the glossy or foil heavy finishes. Some people have been able to partially transfer sublimation images onto matte surfaces, but this is not guaranteed. You may end up with good adhesion, or if you’re not successful, you may end up creating a sublimated image that appears faded or patchy and looks “off".

Another challenge with using Mylar Bags to transfer sublimated images lies in the use of heat. The temperature usually needed to adequately sublimate an image onto something ranges between approximately 375 to 400 degrees Fahrenheit. Based on the specific structure of Mylar, it can typically become warped or wrinkled under this range of heat. Therefore, even if the ink transferred onto the bag, the number of bags that would be useful for infusing will be limited.

Many brands face this challenge after they decide to cut corners with their packaging process. Because sublimation feels quick and easy relative to a small production run; many brands are looking to save time and money during the decision-making process. If you are one of those brands, the article Can You Sublimate on Mylar Bags? will save you time and wasted materials.

Ultimately, sublimation uses Mylar Bags more for experimentation than it is for proven technique. Depending on the materials being used and reasonable expectations, it is possible that sublimation can work. If your company’s goal is to produce a higher quality consistent final package than it is to create a functional and cohesive final product through sublimation, there are other techniques that are better suited to attaining that goal, knowing the reasons for your choices will significantly enhance that likelihood.