DIGITAL TECHNIQUE

There are two digital techniques available for mural creation. Both techniques are completely different from each other. In this section we will review image procurement and each technique's features, benefits and limitations.

Art used for mural creation is available from a great variety of different sources. All art is transferred into a digital image, as the image will be printed. This is usually done by scanning the artwork or by the direct use of art that was originally created on the computer.

Art may be procured from: digital camera photographs, old photographs, Old Master tranparencies of original art, finished paintings by one of the artists in our gallery, commissioned art by one of our artists, an original or past work by the Agape Tile Art Department or non-copyrighted paintings, drawings, lithographs, etc.

A mural's maximum size is governed by the dpi of the scanned image. A high dpi gives a clearer image. A small scanned artwork results in a small maximum mural size. A large scanned artwork will give a larger maximum mural size. At some point, however, the mural size becomes limited, as resolution is lost.

What is dpi? DPI is a measure of spatial printing or dot density. DPI is the number of individual dots that can be placed within the span of one linear inch (2.54 centimeters). Printers with a high DPI produce clearer and more detailed images.

Even though the printer used may be the best on the market, the output will never be a 100% reproduction of the image when viewed on a computer monitor. Should you be proofing an image, that is important to remember. Also, no two computers are alike. Both techniques result in an image that is close to the original art at photographic quality. Images used for both techniques are high resolution, typically 300 to 350 dpi.

Once an image is chosen for a mural it is prepared in Photoshop or another photoediting software program. Images may be cropped to fit the mural size desired. They may also be edited in various other ways, such as changing colors or shape. The entire artwork must then be separated into tile-sized images. These small sections of the entire larger artwork are usually 4x4 or 6x6 inch in size, which is the size of the tile that will be used to accept the image.

KILN FIRED PHOTOGRAPHIC TILE

Kiln fired photographic digital tile murals use 'water-slide' decals. A decal, or transfer, is a substrate that has the artwork printed on it. The art is sent from the computer to the printer.The decals are printed on a laser printer using ceramic toners. A ceramic glaze toner acts like a printing ink, but it is not ink. Ceramic glaze, micro-ground minerals and ores (oxides and salts), are suspended in a liquid to produce a substance that replaces the printer toner, hence the name 'ceramic toner'. Water slide decals (or slip decals) are generally printed face up. After printing each design, it is covered with flux (ground glass) which forms a cover coat. The paper upon which the decal is printed is porous and has a water soluble coating on the back side. The decal is dipped in water prior to its application. Upon contact with water, the glue is loosened from the back and the decal is removed from the paper and 'slid' onto a ceramic wall or porcelain tile. For many years water slide decals have been used for making fine china plates.

As they are laser printed at a high DPI, decals can be produced with a very high level of detail. Until recently, water slide decals were only available in standard designs and each design was printed by the thousands. With the advent of printable decal paper for printers and the invention of ceramic toner, custom decals can now be produced as 'one off' single prints of an artwork.

Prior to firing, the colors are dark or dull or even odd, mere approximations of their post-firing brilliance. Firing in a kiln causes the decals to undergo a dramatic transformation, as the oxides and salts in the ceramic glaze toner fuse and reveal a rich palette of colors. This brilliant image becomes an integral, permanent part of the ceramic material which will not fade with time or exposure to bright sunlight, and can only be removed by mechanical abrasion or by strongly acidic chemicals. During firing the glaze on the underlying tile melts and accepts the decal. This is a permanent process.

During the firing process the covercoat of flux, or ground glass, melts and encapsulates the oxides that are used for color. At the high temperature of the kiln firing, 1650 degrees Fahrenheit, the ceramic glaze on the pre-manufactured tile melts and accepts the decal. The art is fused into the glaze.

Kiln fired photographic digital tile murals are rated for all interior and exterior applicaltions, including high sunlight areas (patios), showers, backsplashes and swimming pools and spas. They are light traffic floor rated. Murals created for freeze thaw areas are done on porcelain, instead of wall tile, and are Frost Proof. All murals are UV Proof and Fire Rated. Murals created using this process are chemical and scratch resistant.

Tile chosen may be smooth porcelain, tumbled or stone-look porcelain or ceramic wall tile (for interior wall installations). The standard finish is semi-gloss. Optional finishes are matte and gloss (upcharge). All murals are done on glazed tile only. Murals done using this technique are photographic quality reproductions.

Should you wish us to produce a mural on your own tile, it cannot be a silk-screened tile. The silk-screening will fire off in the kiln. Should you have a doubt as to whether or not your tile is silk-screened: walk outside, hold the tile up to the light, use a magnifying glass if needed, and look for a dot matrix pattern. If the tile looks dotted, it is silk-screened.

Kiln fired photographic tile using the digital technique is more expensive than dye sublimation as it is more labor intensive.

We produce permanent kiln fired murals on ceramic, porcelain and glass. Our Kiln fired tile has a durable finish and vibrant, vivid colors that will withstand the test of time.

We are capable of producing a digital kiln fired single deco tile or an entire mural. Size is not a limitation. All murals are numbered and graphed for ease in installation. Each tile is numbered on the back.

Kiln fired digital photographic tile is rated for all exterior and interior installations, including showers, fountains, swimming pools and spas and light traffic floors.

We recommend MegaFlex Thin-Set Mortar for mounting. MegaFlex is manufactured by Custom Building Products and is available at DalTile stores and other locations.

Should you break any of your tiles during installation, we will remake them for a nominal cost, plus shipping. We keep all digital files on our murals. You will need to send back each of the surrounding tiles for a match.

We do not use the digital ceramic toner that was developed in Germany by Michael Zimmer and distributed through Digital Ceramic Systems. Our toners achieve rich, bright reds. They were specially formulated to meet our needs as our results from this previous method were unsatisfactory. These toners took over three years to develop. Please see the before and after pictures in this section.

With kiln fired digital photographic tile you can cover the entire exterior of a building and be assured that the mural will look as bright as when it was installed twenty years in the past. The ceramic glaze in our toners give the same longevity as handpainted glazed tile. Kiln fired murals last a lifetime and their longevity is only lessened by a poor installer, unsound substrate or acts of God (earthquake, heavy hail, etc.). Kiln fired tile murals are fire rated.

When you view the images for this section, please note the Oleg Stavrowsky artwork. Images shown are of the old method, our new method and the original artwork. No finished kiln fired mural is ever 100% of the original. Kiln temperatures vary with each fire, even with a computerized kiln system. Temperature and humidity affect the firing result. For mural of 180 + square feet there are typically 9 to 10 tiles that will need to be remade due to a hot or cold spot in the kiln. We use a train kiln to avoid this occurence. Also, please note the artwork 'Beak Experience' by Michael Sussna. You can see the color changes from the original. This is to be expected with a kiln fired mural.

DYE SUBLIMATION - IMAGE SUBLIMATION

Dye Sublimation is the technique of applying an image to specially coated ceramics, metals and polyester cloth, using three main ingredients: sublimation ink, heat and pressure.

Sublimation ink is unique in its ability to convert from a solid to a gas without going through a liquid form. (Just like dry ice.) The conversion is initiated by heat and controlled with pressure and time. Hard substrates, such as ceramic wall tile, porcelain tile, marble or glass, require a special coating to accept the sublimation inks. The materials are purchased with the coating already on them. The sublimation company applies the mural.

Dye sublimation inks are available for large format printers and also desktop inkjet printers for sublimation printing. The image is printed onto a heat transfer paper. This paper has a special finish on the surface so that the inks do not soak into the paper. After printing, the transfer paper it is then placed on the product and heat is applied using a heat press machine. The press heats the material and the print on top to 400 degrees Fahrenheit.

Agape Tile sells image sublimated (dye sublimation) murals and single deco tiles. Murals done using this technique are photographic quality reproductions. Sublimated murals are less costly, easier and to manufacture and take less time to make than kiln fired digital photo murals. With care, they will last for many years. Image Sublimation (Dye Sublimation) is not a permanent material. It has become increasingly popular due to the lower cost. When installed properly, following the material specifications, you may find image sublimation the perfect answer for your custom installation.

Image sublimated murals are available with a gloss, semi-gloss or matte finish. Tile types used are ceramic wall tile, ceramic porcelain tile (smooth, stone-look or tumbled), marble tile (honed, filled or tumbled) and glass. Smooth ceramic wall tile and porcelain give the best results for image reproduction. A tumbled or stone look porcelain tile or marble gives an 'old world' look to the piece. Glass has a modern look. All finished tiles are treated with UV inhibitors to resist fading due to UV rays that are present in INDIRECT sunlight.

The glass tile that we use for sublimation is tempered. Images are applied to the backside of the glass to protect the dyes from wear and abrasion. Tempered glass tiles cannot be cut. We only recommend MegaFlex Ultimate Thin-Set Mortar in White for mounting the textured glass tile in any application. MegaFlex is manufactured by Custom Building Products and is available at DalTile stores and other locations.

All murals are numbered and graphed for ease in installation. Each tile is numbered on the back.

Should you break any of your tiles, we will remake them for a nominal cost, plus shipping. We keep all digital files on our murals.

Before ordering a custom image sublimated mural it is important to understand the material's limitations. This is of great concern to us. There is misleading marketing that is rampant on this product. That statement may seem harsh, but it is true.

Many companies claim that dye sublimation is durable and lasting and that the image is actually 'under the surface' of the tile. In reality, the image and the coating are sitting on top of the hard substrate (ceramic, porcelain, marble or glass tile). The glaze on the tile has not melted and accepted the artwork within its chemical structure. Glaze does not melt at 400 degrees Fahrenheit. The artwork is not 'impregnated' into the tile. It is impregnated into the coating on the tile. Others mention that their process of dye sublimation is better than a decal that is 'laying' on the surface. A ceramic decal is kiln fired INTO the underlying glaze.

Beware of claims that are made that the UV coating (laminate overcoat) that has been applied on top of the finished piece renders the material rated for exterior installations. We speak from experience, as we have tested this product. You CANNOT install a sublimated mural outdoors in sunlight. The mural will fade. Over time, the entire mural will peel off of the tile. The coating does render the piece more water resistant, which is important, as sublimated murals are manufactured on non-vitreous ceramic wall tile. Dye Sublimation murals are rated for interior wall installations only.

If you take a kiln fired digital photo tile, and apply heat from a blowtorch, there are no negative results. A blowtorch applied to an image sublimated tile will peel off the entire top coating (mural). The image that has been transferred to the substrate using heat and pressure is not permanent.

Sublimation murals are 'scratch resistant', however, they are easily scratched by any sharp instrument and great care needs to be taken during and after installation. You cannot use a sublimated mural on a floor. Please review the installation and maintenance information at the end of this section.

The test...if you are purchasing your mural elsewhere, read the maintenance and installation instructions presented by the company. If the specifications mention using unsanded grout and grouting the joints only, the tile is sublimated.

Why have we spent so much time imparting this seemingly negative information on sublimation murals? Because we wish our customers to fully comprehend their limitations. Sublimation tile murals are beautiful, economical and photo realistic. We wish our customers to be fully informed. No one should have to be greeted with disappointment when their mural is lost due to misplacement in installation.

KILN FIRED PHOTOGRAPHIC MURAL MAINTENANCE

You may use a sanded or un-sanded grout. Kiln fired tile is scratch resistant, however, you may dull the finish if you press too hard with an abrasive substance. Wipe off excess grout with a soft cloth or sponge. Rinse and clean with a soft cloth. Apply grout sealer after waiting 30 days, following the manufacturer's directions.

It is not necessary to use detergent. Detergent leaves a film that will dull the appearance of the tile. In the case of tile with a high-gloss finish, use Windex to remove any water streaks.

Do not use commercial tile cleaners, commercial fungicides, chlorine bleach, acids, detergent or ammonia. The use of abrasive household cleaners is not recommended. Abrasive and acidic cleaners cause a minute etching on the tile finish. Read all cleaning product directions prior to use. Do not use steel wool or steel scrub pads on your tile or grout, as it will dull the finish. The same is true of all types of tile.

IMAGE SUBLIMATED - DYE SUBLIMATION - MURAL MAINTENANCE

Always use an un-sanded grout. Image sublimated tile is not scratchproof. Do not grout the entire surface, just the joints. Wipe carefully with a soft cloth. Do not rub. Clean as soon as possible with a mild solution of half a capfull of Windex and a soft cloth. T-shirt material is recommended as your soft cloth. Apply grout sealer to the joint after 30 days, following the manufacturers directions. Rinse and clean with a soft cloth.

The use of multi-purpose household cleaners is not recommended. It is not be necessary to use any type of detergent. Detergent leaves a film that will dull the appearance of the tile. In the case of tile with a high-gloss finish, one cap-full of Windex can be added to one quart of warm water to remove any water streaks. For kitchen backsplashes, clean often after cooking to prevent dirt buildup. Do not use commercial tile cleaners, commercial fungicides, chlorine bleach, abrasive cleansers, detergent, ammonia or petroleum or animal fat-based cleaners. Read all cleansing product directions prior to use. Do not use acids of any type (hydrofluoric or muriatic) on your tile or grout. Do not use steel wood, colored cleansing agents or scrub pads. Do not wax your tile. Image sublimated murals are durable, with proper care and maintenance.

Do not use sublimated tile outdoors or in fountains, swimming pools or spas. We do not recommend the use of image sublimated tile in shower areas. If you do use sublimated tiles in your shower they will require frequent periodic cleaning in order to remove soap scum, hard water deposits and body oil. Over time the mural will be damaged.

CUSTOM MURALS

Most of our work is custom and ranges from one tile to an entire wall or floor. Most customers cannot tell the difference between image sublimation and kiln fired murals. All murals are custom and are available in any size to fit an installation. All murals are special order. No matter what you envision, we can create it.

For further information on our products or custom murals please call us at 888-680-8453. We are looking forward to creating for you.