Sublimation on Hard Blanks: Beyond the T-Shirt
Sublimation isn't just for garments. One of the most exciting aspects of sublimation printing is how well it works on a wide range of hard sublimation blanks — especially small, giftable items like puzzles, ornaments, and keychains. These products are perennial bestsellers for holidays, birthdays, weddings, and memorials, and sublimation produces full-color, photo-quality prints on them with no peeling, cracking, or fading.
This guide covers the three most popular small sublimation blank categories: puzzles, ornaments, and keychains. (New to sublimation? Start with our guide to the best sublimation blanks for beginners.)
Sublimation Puzzles
Custom photo puzzles are one of the most popular personalized gift items on the market. Sublimation puzzles are made from a hardboard or MDF base with a special polymer coating that accepts sublimation dye.
What to know about sublimation puzzles:
- Blank types: Sublimation puzzles typically come in 30, 100, 252, and 500 piece counts. They're usually 11"x8.5" or similar proportions.
- Design sizing: Design your image to match the puzzle dimensions exactly. Use a template if available from your blank supplier to account for the full bleed area.
- Press settings: 380-400 degrees F, 60 seconds, firm pressure
- Application: Tape your transfer to the blank, cover with a PTFE sheet, and press. The puzzle pieces can shift slightly if not held together — use puzzle holder frames or tape the assembled puzzle before pressing.
- Pro tip: Place the puzzle on a silicone pad on the press to prevent the pieces from separating under pressure.
Sublimation Ornaments
Custom Christmas ornaments are one of the hottest seasonal sellers for sublimation decorators. Sublimation ornaments are typically round, heart-shaped, or star-shaped acrylic or MDF blanks with a polymer-coated surface.
What to know about sublimation ornaments:
- Blank types: Acrylic ornaments (typically clear or white with a coated face), MDF ornaments (wood-like base with sublimation coating), and aluminum ornaments
- Shape variety: Circles, ovals, hearts, stars, Christmas trees, houses, and more
- Design sizing: Use a template sized to the exact ornament dimensions. Leave some extra on round/shaped edges for a clean bleed.
- Press settings: 380-400 degrees F, 45-60 seconds, light-medium pressure
- Application: Tape the transfer to the sublimation face of the ornament. Use a small silicone pad under the ornament for even pressure. Do not press from the back of the ornament.
- Packaging tip: Sublimated ornaments packaged in clear bags with ribbon are a popular and attractive retail presentation. For more product inspiration, browse our 25 easy sublimation gift ideas that sell.
Sublimation Keychains
Custom keychains are a low-cost, high-margin product that sells well year-round. Sublimation keychains come in acrylic, aluminum, and MDF varieties.
What to know about sublimation keychains:
- Blank types: Acrylic (most common), aluminum, and MDF. Most come with a split ring attachment already included.
- Shape variety: Rectangle, circle, oval, dog bone, house, star, heart, and custom shapes
- Design sizing: Most sublimation keychains are small — typically 1.5"x2.5" to 2"x3". Design your artwork at the exact size and at 300 DPI for sharp results.
- Press settings: 380-400 degrees F, 45-60 seconds, firm pressure
- Multiple keychains at once: You can press multiple keychains on one sheet in a single press cycle, which makes production very efficient.
- Profit margins: Sublimation keychains are typically among the highest-margin products a sublimation decorator can offer. Blanks cost $1-2, and custom keychains sell for $8-15 each at retail.
General Tips for Small Sublimation Blanks
- Always use a silicone pad or foam pad underneath small blanks to ensure even pressure.
- Use heat-resistant tape to secure transfers precisely — small blanks have little margin for error.
- Work with a clam-shell press or a mug press depending on the blank type.
- Test your press settings on a scrap blank before committing to a production run.
- Allow blanks to cool completely before peeling the transfer to avoid ghosting.
Order Sublimation Transfers at Atlanta Vinyl
Atlanta Vinyl offers custom sublimation transfers in any size, including small sizes perfect for ornaments, keychains, and puzzle panels. We also carry sublimation blanks and all the sublimation supplies you need for your holiday and gift product line. Order online for fast turnaround.