Plastisol heat transfers offer a flexible, efficient way to produce high-quality, durable prints for garments, especially when direct screen printing isn’t the most practical option. Whether you're managing bulk orders, printing on difficult fabrics, or simply seeking more inventory flexibility, plastisol transfers allow you to print now and press later, minimizing waste and speeding up turnaround.

In this article, we’ll explore what plastisol transfers are, the tools and steps you’ll need to make them properly, and how to avoid common pitfalls. Whether you’re just starting out or refining your production process, mastering this technique will enhance the versatility of your screen printing operation.


What are plastisol transfers?

Definition and advantages

Plastisol transfers are screen-printed designs created using plastisol ink on a special type of transfer paper. These prints are not cured completely during production, instead, they’re partially gelled and then heat-applied to garments later using a heat press.

Key advantages include:

  • On-demand printing: stock up on designs and press as needed.

  • Less mess and downtime: ideal for small print runs or pop-up shops.

  • Greater control over placement and garment types.

  • Crisp, vibrant results on a wide range of fabrics.

When to use heat transfers vs. direct printing

Plastisol transfers are preferable when:

  • You want to print on location or at a later time.

  • You have large designs or multi-color images requiring registration precision.

  • You’re working with sensitive or irregular fabrics that are difficult to load onto a screen printing press.

  • You need to fulfill variable orders quickly without setting up screens every time.

Direct printing is best for large batches on a consistent garment type with fewer design variations. But for flexibility and on-demand fulfillment, heat transfers are a game-changer.


Materials and equipment needed

Plastisol ink, transfer paper, screen printing setup

To create plastisol heat transfers, you’ll need:

  • Plastisol ink – formulated for screen printing and heat transfer use.

  • Transfer paper – coated to accept and release ink during heat application.

  • Screen printing setup – ideally a multicolor press with accurate registration.

Use high-quality paper specifically designed for plastisol transfers; not all papers will withstand the curing process or release the ink cleanly.

Heat press with temperature and pressure control

A reliable heat press is critical for success. It must offer:

  • Accurate temperature control (typically 325–350°F).

  • Consistent, even pressure (medium to firm).

  • Timer functions for consistent application.

A swing-away or clamshell press both work, as long as heat and pressure are evenly distributed.


Step-by-step process

Step 1: Design preparation

Start by preparing your design using graphic software like Adobe Illustrator or CorelDRAW. Mirror (flip) the design horizontally, since it will be reversed during transfer. Separate colors if using multiple screens, and burn each screen as usual for screen printing.

Step 2: Printing the image in reverse on transfer paper

Load your transfer paper onto the platen, and print the design in reverse using plastisol ink. Maintain proper off-contact and flood strokes to ensure even ink distribution.

For multi-color transfers, allow each color to flash cure before applying the next to avoid smearing.

Step 3: Gel curing the ink (not fully curing)

Once printed, pass the paper through a flash dryer or conveyor dryer to gel the ink—this means curing it partially so it is dry to the touch but not fully fused.

  • Gel temp: around 180–250°F (82–121°C)

  • Do not exceed full cure temperature (around 320–330°F / 160–165°C)

Over-curing now will prevent the ink from releasing properly during the final heat press step.

Step 4: Cooling and storing transfers

Allow the sheets to cool flat, then store them in a dry, clean place. They can be used immediately or weeks later, offering great flexibility.

To avoid contamination or smudging, store them flat in a container or sleeve and keep away from heat sources.

Step 5: Applying the transfer with a heat press

Position the cooled transfer on the garment (ink side down) and use a heat press set to the appropriate time, temperature, and pressure:

  • Temp: 325–350°F (163–177°C)

  • Time: 8–12 seconds

  • Pressure: medium to firm

Peel instructions vary: hot peel or cold peel, depending on your transfer paper and ink combination. Always test before full production.


Troubleshooting common issues

Ink not releasing from transfer paper

If the ink doesn’t transfer to the garment, possible reasons include:

  • Over-curing during the gel phase

  • Insufficient pressure or heat during pressing

  • Wrong type of transfer paper

  • Waiting too long to peel (for hot-peel setups)

Solution: Retest your curing and pressing settings, and ensure the right materials are being used.

Cracked or incomplete transfers

Cracks or incomplete prints often stem from:

  • Inadequate pressure

  • Uneven heat across the platen

  • A garment that shifted during pressing

Double-check your heat press calibration and always pre-press garments to remove moisture and flatten wrinkles before application.


Tips for long-lasting results

Optimal temperature and pressure settings

Every plastisol ink and transfer paper combo has an ideal heat profile. Stick to the manufacturer’s guidelines, but test on your own fabrics to fine-tune:

  • Start with 330°F for 10 seconds under medium-firm pressure.

  • Adjust if ink doesn’t adhere well or releases unevenly.

Avoid over-pressing, which can burn the paper or distort the ink.

Storage and handling of finished transfers

To maximize shelf life and reliability:

  • Store transfers flat, in a dry area, ideally in a folder or envelope.

  • Avoid heat, humidity, or stacking too tightly.

  • Label your transfers by design and date to manage usage easily.

With proper care, plastisol transfers can remain usable for several months, making them ideal for seasonal or recurring orders.

Conclusion

Plastisol heat transfers combine the quality of screen printing with the flexibility of on-demand production. By mastering the right materials, printing techniques, and heat application steps, you can produce vibrant, durable designs with greater control and efficiency. Whether you're scaling up your shop or exploring new workflows, this method opens the door to faster turnarounds, cleaner prints, and versatile garment options: all without sacrificing quality.