How to make a tapered tumbler wrap from a straight design
A straight design won't sit right on a tapered cup. Here's the whole process, from tape measure to a wrap that meets cleanly at the seam.
What you need
- Your tapered tumbler blank and a soft measuring tape
- Your design as a straight, rectangular wrap (PNG or JPG)
- Sublimation paper large enough for the curved wrap: usually Tabloid or A3 (TaperWrap shows which papers fit your cup)
- Scissors or a cutting machine, heat-resistant tape and your usual pressing setup
Step 1: Measure the cup
Measure around the cup just under the lid line (top circumference) and just above the base (bottom circumference). Then measure the height between those two lines along the side of the cup. Write all three down. They're the only numbers you need. For exactly where to put the tape, see how to measure a tumbler for sublimation.
Printing a 40 oz tumbler with a handle? Those are printed in two pieces with a plain band between them; the 40 oz tumbler sublimation template guide covers measuring each piece.
Step 2: Warp the design
Open TaperWrap, upload your straight design and enter the three measurements. The preview shows your design bent into the curved shape of your cup. Under Print options you can add a seam overlap (about ¼ in / 6 mm is common) and a little bleed at the top and bottom if your blank has no clear print edge.
Step 3: Check the print size
TaperWrap shows the finished size and which papers it fits. The curve doesn't make the wrap wider: the flat template is about as wide as the cup's widest circumference plus the seam overlap. What the curve adds is a little height, and that's enough to make the common tapered 20 and 30 oz wraps too tall for Letter, A4 or Legal. Print those on Tabloid or A3 in one piece, or let TaperWrap split them into two pieces for Letter or A4. Legal fits only short, strongly tapered cups such as the Make Market 19 oz; the tapered tumbler template guide gives the sizes. To check before you buy blanks or paper, the tumbler template sizes list shows the flat template size of cups by brand and model.
Step 4: Print at actual size
Download the PDF for your paper size and print at Actual size / 100%, never "Fit to page", which shrinks the wrap so it won't reach around the cup. If you print from design software instead, use the PNG. It's tagged with its DPI so it opens at true size. Mirror the image only if your usual workflow for this printer and paper needs it.
Step 5: Trim and test-fit
Cut along the printed cut line. Before pressing, wrap the paper around the cup. The top edge should follow the rim and the ends should meet or slightly overlap at the seam. If there's a gap, re-measure: a small measuring error is almost always the cause.
Step 6: Secure and press
Tape the wrap tightly, print side against the cup, and press or bake following the time and temperature your blank's maker recommends. Tapered cups need even contact from rim to base, so use a shrink sleeve or a press designed for tapered tumblers.
Troubleshooting
There's a gap at the seam near the top
The top circumference was measured too small, or the page was scaled when printing. Check that the printer was set to 100%.
The design looks tilted at the seam
That happens when a rectangle is wrapped around a cone. A properly warped wrap keeps every row level, so make sure you're printing the warped file and not the original.
Text looks slightly wider at the top
That's expected. Every row of the design has to reach all the way around the cup, and the top is wider, so rows near the rim are stretched a little more than rows near the base. On most tapered cups the difference is small.
