Kitesurf365: TechCast #26 – Printing Processes | Episode #422

Date: January 26, 2026
Host: Adrian Kerr
Guest: Dave K (“DK”)

Overview

In this highly technical “TechCast” episode, Adrian and DK dive deep into the world of printing processes as they pertain to kiteboarding equipment—from traditional screen printing to modern digital and sublimation techniques. With recent developments in printing at the forefront of kite design (notably from Brainchild and now Nash), the conversation aims to inform and demystify how graphics affect both design and performance, and what the future may hold for visual innovation and production in the kite industry.

Key Discussion Points & Insights

1. Why Printing Matters in Kiteboarding

• Printing impacts more than just aesthetics—it affects durability, manufacturing complexity, and even overall product design.
• Quote:

  “Printing is non trivial. Like, it’s actually, it’s an integral part of the design and build process… there are some types of printing process that can have physical effects on the kite.”
  — DK [02:47]

2. Traditional Screen Printing: The Industry Standard

How Screen Printing Works

• Uses a fabric mesh stretched over a frame (once silk, now polyester/nylon).
• The mesh is coated with a photosensitive emulsion, selectively exposed to UV to form the design, then ink is pressed through using a rubber squeegee.
• Typically performed in rows on adhesive-covered tables where fabric is laid out flat.

Notable Moment:

“It’s a relatively low tech process, but it requires some very, very skilled people for all of those things to line up…”
— DK [28:47]

Upsides of Screen Printing

• Cost-effective for small areas and limited color work.
• Extremely durable and allows for vibrant “spot” and metallic colors not possible with digital printing.

  “Screen printing is really good for big bold single color areas…but completely unsuitable for photographic quality.”
  — DK [17:46]

Downsides

• Toxic solvents and inks (significant waste disposal and factory licensing issues, especially in China).
• Labor-intensive and slow, especially with multiple colors (each requiring separate screens and curing time).
• Limited resolution (typically 75 DPI) and color variety.

  “Every color that you do requires a separate screen and a separate path…for a single color screen printing is incredibly effective, but its cost to effectiveness ratio just plummets as you start adding extra colors.”
  — DK [19:28]

3. Pad Printing: For 3D or Irregular Surfaces

• Uses a flexible silicon pad to transfer ink onto uneven, small objects (e.g., fins, handles, EVA on control bars).

• Limited to small detail work and one or two colors; not suited for large surfaces.

  “Definitely the go-to for any sort of 3D shaped object.”
  — DK [25:44]

4. Digital Printing: The Game-Changer for Boards

• Now standard for twin tip kiteboards, enabling full-color, high-res graphics (up to 1200 DPI).

• Utilizes eco-solvent inkjets to apply direct-to-surface prints on clear TPU sheets, with a white screen-printed layer behind to make colors pop.

• Environmentally friendlier (except for still needing one white screen backing).

  “What it gives us is the ability to print 16 million colors…photographic quality printing.”
  — DK [30:44]

5. Dye Sublimation Printing: The Latest Wave for Kites

How Sublimation Works

• Designs are printed (mirrored) onto special paper using sublimation inks, then pressed under heat (≈200°C) onto polyester substrates.

• The ink turns to gas and infuses the fabric—graphics are “in” the material, not just on top.

  “This is like alchemy…how on earth was that invented?”
  — DK [36:19]

Advantages

• Unlimited color and photographic detail (think: 16.7 million colors, 1200 DPI).
• Far more design freedom and manufacturing flexibility; every kite could technically be unique.
• Major reduction in color limitations and fabric inventory—only white base is needed.

  “If you are 100% digitally printing every panel on your kite you only need to stock white fabric.”
  — DK [51:52]

Challenges

• Requires uncoated or specially-formulated polyester; traditional coatings (used for durability in kite canopies) often resist ink or degrade under heat.
• Shrinkage during high-heat transfer: fabric must be pre-characterized and printed slightly larger.
• UV instability: Historically, dye sub prints fade faster, and white polyester yellows in sun.
• Durability and longevity still to be definitively proven, though factories like Brainchild claim to have resolved these issues.

  “Feedback I’ve had from other kite brands…is [this process] negatively affects the fabric and the lifespan of the fabric.”
  — DK [44:00]

• Custom jobs are possible, but preparation and setup add cost—even though each kite can be different.

  “It's costly from the preparation for printing, probably costs a little bit ... there's a, there's a second side to this that is probably not as obvious...”
  — DK [51:52]

6. Industry Trends and Adoption: Who’s Doing What?

Brainchild

• Early adopter of full-panel dye sublimation kites.
• Collaboration with suppliers like Porsche to develop compatible fabrics.
• Claims to have overcome shrinkage, coating, and UV resistance hurdles.

Nash

• New Nash kites use sublimation/digital printing, leading to confusion with Brainchild designs.
• Part of a wider industry movement; visual distinctiveness and flexibility are selling points.

Other Brands and Future

• Adoption is expanding as factories and suppliers develop compatible materials and refine the process.

• The ability to quickly prototype, produce in small batches, or even customize each kite is revolutionary for manufacturing and design.

  “I believe it’s the future…digital printing onto kites is definitely the future…It might not be dye sublimation printing…[but] everyone else is working on it.”
  — DK [55:32]

Notable Quotes & Moments

• On the significance of printing:
  “As a product manager…it can take many, many times longer [to sort out] the graphics on twin tip boards than actually sorting out the engineering of the board.”
  — DK [01:35]
• On environmental drawbacks:
  “…the solvents needed to actually clean out the screens at the end…are quite toxic…That is not only those solvents are not only expensive, not only expensive, they're quite toxic…”
  — DK [14:41]
• On the vibrancy of screen printing:
  “Screen printing colors are generally much deeper…there is just literally more ink and more tint and so you get a much bolder, much more vibrant color…”
  — DK [21:17]
• On the creative freedom of digital processes:
  “Photographic quality printing gives your graphic artist free rein to create anything they like…”
  — DK [50:19]
• On the future direction:
  “The Brainchild factory was the first to sort of commit to it. Everyone else is…working on it. I’ve seen, I’ve seen pictures go up online of test prints…”
  — DK [56:55]

Key Timestamps

• 00:00 – Episode intro, why printing is a hot topic
• 01:06–02:47 – Industry context: Brainchild and Nash pushing new printing methods
• 04:00–13:17 – Detailed breakdown of screen printing processes on kites and boards
• 13:27–22:22 – Pros/cons of screen printing, color limitations, environmental impacts
• 23:43–28:37 – Pad printing explained for small, irregular parts
• 30:44–35:20 – Digital printing’s emergence in twin tips; photographic graphics
• 36:00–44:00 – Sublimation printing: science, advantages, and production challenges
• 49:14–52:05 – Why major brands (Nash, Brainchild, Harlem) are shifting to digital/sublimation prints
• 54:05–57:36 – Will digital printing become the industry standard?
• 57:36–58:14 – Wrap-up and farewell

Conclusion

This episode demystifies the technical realities behind printing processes in kiteboarding, revealing how advances in graphics manufacturing are shaping both the products and the business of kiting. With Brainchild and Nash leading the way, it’s clear that digitally-driven methods—especially dye sublimation—offer compelling creative and operational advantages, though durability and UV resistance remain closely watched. Expect more brands to follow as materials, machinery, and knowledge catch up, and as the industry seeks both greater design freedom and more sustainable production.

Final Reflection:

“Everything in life is a compromise, including printing.”
— DK [21:52]

For anyone interested in the intersection of design, technology, and performance in kiteboarding, this episode is a must-listen deep dive into a rapidly-evolving facet of the sport.