Direct-to-Film Printing Technology and Textile Applications Explored
Direct-to-film (DTF) printing on apparel is having a significant impact on the decorated clothing market. This growing technology, which was once the domain of small craftsmen and women, is now offered by machine manufacturers in industrial solutions that are more effective. In a global market for DTG (direct-to-garment) printing that is predicted to reach nearly US$1.9 billion by 2032, the DTF process is gaining ground by the month—as it offers new and unique advantages to trade printers. This article by WhatTheyThink contributor Debbie McKeegan, a textiles expert, provides more information.
Image courtesy of Texintel
Direct-to-film (DTF) apparel printing has a significant impact on the decorated clothing market. Machine manufacturers now offer ever-more successful industrial solutions for this growing technology—that just a few years ago seemed to be the preserve of the small craft manufacturer.
DTF (direct-to fabric) is gaining momentum in a DTG market, which is expected to reach US$1.9billion by 2032. This is because it offers trade printers new and unique benefits.
The DTF Process
DTF prints begin by printing images with water-based pigments onto PET film. The image is reverse printed because it must be transferred. After ink-jet printing, the wet image is powdered and cured with hot melt adhesive. The image can then be transferred to a garment with a heat press.
DTF has several advantages over DTG:
First, the DTF process does not require pre-treatment and it can be applied to many types of fiber compositions—polyester, cotton, nylon, and mixed fiber blends can all be printed using the DTF method. DTF printing offers vibrant output and a wide color range (results vary based on ink vendor).
The quality of print can also be described as exceptional, since lines, small fonts and fine details can be printed with accuracy due to the surface regularity inherent in PET film.
DTF prints also improve the garment’s handle and stretchability, owing to their lower solid mass.
DTF Economics
DTF’s economic model is based on the simplicity of the DTF printing process. It is easy to understand and simple to implement. The digital printing process for a PET film substrate is similar to that of a paper poster or other common print media. DTF printing works well for a small business or an industrial operation, because it is simple to use and requires little space.
Printing costs, despite the added cost of powder and film, are estimated to range between $0.50 and $0.75 per meter. This is a significant economic gain for both large-scale industrial operations and independent printers in the apparel industry.
The process has the advantage that DTF can be printed at high speeds. Once the film is printed, it can be stored until the transfer process. As a result, apparel production print speed will not be compromised by the traditional workflow.
When the film is eventually used, its applications are wide and varied: typically, T-shirts, hoodies, sportswear, promotional items, and even interior décor offer commercial opportunities for the DTF process using a film produced at the lowest possible price.
DTF is the latest and most popular trend in apparel decoration. This is because the combination of print speeds and separate image transfers generates enormous savings during the production process.
DTF Machinery
Originally, DTF printing, which started at a very small, affordable scale, was the preserve of standard inkjet printers—desktop machines using specific inks for textile use and these were readily available from a multitude of manufacturers.
As DTF printing has evolved to offer significant advantages, including no fabric limitations and faster printing innovations, many major digital printer manufacturers are now offering a variety of machines with variable speeds and affordable entry prices. With time, the technology has improved to allow this sector to adopt an industrial process.
Recently Mimaki released their TXF15075 which marked their entry in this premium branded clothing market. Mark Sollman is a Senior. Mark Sollman, Sr.
Apparel decoration, a popular and dynamic industry that we already operate in with other textile technologies, is one of the most exciting areas. In recent years we have seen the positive impact of DTF technology on the textile industry, as it offers significant advantages to existing technologies. DTF, for example, eliminates the lengthy process of creating plates in screen printing as well as the weeding required in vinyl heat transfers. Full color printing is also possible with this technology. We’re excited to bring a solution to the market that is designed for those already active in the decorated apparel sector and those looking to enter it -which excels in usability, reliability and quality.
Ricoh announced that they will be releasing a DTF retrofit in 2022 for their Ri 1000 and Ri2000 DTG capabilities. This allows a simple conversion to the new DTG process.
Axel Stuhlreiter commented on the comment made by Axel Stuhlreiter.
The innovative technology enhances the versatility and flexibility of Ricoh’s leading DTG printers. They can be converted in a few easy steps to allow DTF printing onto a variety of materials, and deliver a wider range of applications. This simple and fast process produces highly creative results in a short time.
Sublistar STAR-IV Series DTFP Printer, manufactured in China, became available to the public in 2023. It includes a balanced in-line print, powder shakers, moisturizing agents, and fixation driers, allowing for fast and error-free printing.
Beyond these, in 2022 there were DTF offerings from Epson, Brother, Mutoh, Resolute, Pigment.inc, and Roland—all of which reflected the growing attraction of the DTF market, which a trade commentator recently described as being one of the ”newest and hottest trends in the decorated apparel industry.”
DTF is here and has a bright future. With a variety of machines on the market and the ability to print on any fabric, it offers undeniable production benefits.
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