Hmm this is interesting...what is the label inside of the core say? it almost looks like the vinyl delaminated from the adhesive...
Not real impressed with the one that "looks great" either. Should be opaque.
grrr...have you been able to reproduce this?
well that's a plus...dye sub jersey's are so tough with heat transfer. keep me posted on this...i would venture to say the customer dried at a high temp
I use Stahls ThermoFilm on dye sub jerseys (mainly motocross) and have never had a problem with opaqueness or washing.
Did you ask the customer how they washed/dried it? Are you sure you used the proper settings when you pressed it? Did it look good when it left your shop?
the thing with dye migration is it doesn't happen immediately. It can sometimes take a day or more. The heat is what causes this. It is basically re-activating the dyes in the fabric.
I always stress to never dry a dye-sub jersey that has a transfer on it.