Direct-to-film, or most commonly referred to as DTF, is a revolutionary embellishment process.

What makes this technology so remarkable is for the first time in my 26 years as an embellishment educator and printer, we have an affordable, no-limitation transfer option. Let me explain.

Basic Benefits

Using the right mix of the printer and consumables (explained later in the article) or DTF print provider service, we can create full-color transfers with no color or textile limitations and without artwork limitations, no weeding, and that are soft to the hand. There’s no pre-treating, no true two-step process, no/limited heat concerns, transfers are printed at high speeds and at low cost. Plus, they are nearly indestructible (I’ve heard reports of 50 to 75-plus washed with little to no fad) and can either be made in house or quickly delivered from print providers.

Think about that. One process, for all color garments, nearly all textiles (poly, cottons, blends, nylon, leather, spandex, etc.) that can be applied at temps from 250-310-plus F with as little as five-second dwell time on certain fabrics. (Note: Always test and check with your supplier for time, temps, and pressure recommendations. Results will vary — it takes time to dial in, but when you get it, your got it!).

I love heat transfer vinyl (HTV), but take away 50-90% of the labor, cut the cost by 30-75%, and remove artwork limitations while creating as soft or in most cases, a much softer hand, and DTF is going to win almost every time. This does not mean you toss away your print/cut devices, just be aware of the best new way to decorate apparel and textiles.

Dye-sublimation is the bees’ knees when it comes the feel or hand of a transfer. I am partners in a dye-sub print cut-and-sew/decorating company, but this process does not allow for the number-one requested apparel item: a printed black/dark cotton T-shirt or hoodie. The heat needed for sublimation also eliminates a lot of low-temperature transfer opportunities.

Now, for a small-medium investment, every dye-sub shop has an option to address decorating needs for all apparel and textiles!

For about a $1 per sq. ft. or less, you can produce these transfers in-house using high-quality materials. Ordering transfers from service providers clients can expect to pay about $3.00-$7.50-plus per sq. ft. or sheet. This low-cost, high-quality transfer has led to a boom in people offering transfers as a service. A commercial DTF printer can print at 50-150-plus sq. ft. per hour, creating a revenue stream of $100-$500-plus per hour offering DTF printing services per machine (before labor and overhead). You can expect to spend about $20,000-$30,000-plus on a good commercial set-up from a reputable supplier.

The DTF Process

The process, simplified, requires the following (speaking from a large-format, 24” or larger platform):

• Printer
• RIP software
• DTF inks
• DTF film
• DTF powder
• Curing device/powder shaker
• Heat press
• Safety procedure for powdering, curing, and ventilating

The first requirement is a printer, 24” or larger generally with Epson print head(s), that is capable of printing a minimum of five colors (CMYK, plus white). Most of the commercial systems have two or more heads. This allows one or more of the heads to be dedicated for the white ink.

These printers also have some type of bulk system and mixing or circulation pumps for the white ink. This means that the user does not have to manually shake or stir inks that are put into the machine. Ink can settle after time, so it’s always best to get advice from your dealer or manufacturer.

Most of these machines are currently coming from China, with many other big name printer manufacturers taking notice and entering the space. As these machines require service and maintenance, my recommendation is always look at the accessibility of the head(s), capping station, ink lines, media access, and other key elements to keep your printer printing.

The next item to focus on is RIP software. We are speaking about commercial printers running a white ink, so for the purpose of keeping this brief, I’ll assume most are aware of the need of the RIP to control printing, colors, placement of the white, ability to profile, and optimal workflow.

What I will go into detail on are names like CADLink/EFI, Wasatch, Flexi, and others offering solutions for DTF that were not available in 2021. This is quickly giving printing shops the confidence to move forward with DTF in-house solutions as most are familiar with these software companies.

Dealers and end users struggled in the beginning of DTF as all were forced with limited overseas “support” and RIP education.

Consumables and supplies

I’m no chemist, so I’m not going to geek out on any of these too much, but rather just share the experience of those much smatter then I and with more hands-on experience.

You want a supplier/manufacturer with water-based ink embellishment technology. Folks making dye-sub, eco-solvent, and other digital inks for thermal piezo and continuous inkjet systems are best to deal with based on their experience. The top thing I’ll say is, if you find something that works, stick with it. Dealers or manufacturers who change things a lot often introduce unwanted variables.

The ‘F’ in DTF in for Film (get your minds out the gutter 😊). The film is PET film, usually .75-1mm in thickness. This is thicker than traditional screen-print transfers, making the printing process on rolls and sheets easier and more consistent than a paper. Using the above inks, we have two of the three pieces to create that universal/unicorn of a transfer.

The powder, or hot-melt adhesive, bonds this whole process together.

The often 80-200-micron white granular powder settles onto the printed white ink while the ink is still slightly wet. The powder is then cured using a conveyor dryer, powder/shaker, heat press, or other curing device. When this process is completed, you have a transfer that’s ready to apply or ship.

There are different grades if powder, so check with your supplier on what they recommend for your application.

There are several safety concerns to take into consideration. You want a well-ventilated area, with any fumes directed outside or into a filter, and proper handling while loading powder and doing the process manually. Your reseller should provide all this information. If not, find one that does.

It’s always a good idea to ask your supplier or manufacture if the materials they offer are Oeko-Tex certified. Oeko-Tex certifies non-hazardous end products and all of their components. Products that carry the Standard 100 label have been tested and proven free of harmful levels of toxic substances.

Something many printers forget about that’s important is the materials we print with and offer should be as safe as possible, for our employees and those purchasing the apparel. This is usually a sign of consistency of manufacturing too.

Things are changing, so try to be informed from your supplier what to expect. The good news is companies like DTF2U offer complete solutions, and with large global manufacturers like Kodak entering the arena (KODACOLOR Ink, Film, Powder, and Cleaning Consumable Solution) as well as others, the future of high-quality, consistent manufacturing and availability looks bright!

After the prints come out of the commercial printer, they go in line with an automatic adhesive powder shaker. These take over by evenly spreading then melting the exact amount of hot melt adhesive material directly onto your design, saving time, effort, and cost versus manual application and curing in an oven or press. These units all come ready for ventilation with an exhaust outlet.

They come in several varieties with more features like longer drying tunnels for machines that print faster or auto recycling for the powder. Check weight, size, and electrical for these machines. Not all shops or homes can receive and plug-and-play with these units.

For those handling powdering, can use a film curing oven or heat press to cure the printing, usually 220-250 F at 1-2 minutes.

Now that we have our printer and cured transfer, it’s time to press it. You want a decent commercial press with accurate time, temperature, and presses. Press times can range from 250-260 F, five seconds, medium pressure, peel hot or cold (depending on the film used) on a poly or heat sensitive fabric, all the way up to 305-315 F, 10-15 seconds, and medium pressure on cotton or heavier textiles substrates. Ask and test before diving into production.

Maintenance Procedures

There is maintenance. As mentioned, look for machines with auto or easy cleaning options and machines with easy accessibility to key maintenance areas.

Large-format/commercial solutions are almost always easier, faster, and less costly overall to upkeep, and there are plenty of options. Give yourself at least a few days after an onsite install and a few weeks to months for an install you might do yourself. The more inkjet and DTG experience you have, the quicker you’ll find your comfort zone.  Check with you supplier on what’s truly expected.

It takes space. Most commercial equipment is big and heavy. Check on the required and recommended footprint and electrical needs. Almost all the powder/duster/dryers will require 220v. From a receiving standpoint, a liftgate alone will not always be enough to remove the equipment upon arrival.

These machines must be exhausted outside or through an industrial filtration system, similar to laser engraving/cutting, UV printing, and rotary dye-sub pressing. There are fumes and chemical reactions taking place, and you need a safe working environment. Usually a small exhaust fan, some tubing, and exit hole is all that’s needed. This can have an added cost of a few hundred dollars for a do it yourself, and up to several thousand if more labor is needed or you go with an industrial filtration system.

A Revolutionary Process

The biggest challenges of 2021 were supply chain and product consistency. A lot of that has been addressed in 2022 as resellers and end users settled upon consistent manufacturing and proper scaling of inventory. This problem won’t go away completely, but the right reseller or print provider should have contingencies in place. Logistics of machines based on demand is also a struggle.

For the end user with new equipment, it’s like any other purchase: Become comfortable with the process, put a support system in place, and dial the process in for you, your team, and your clients upon receiving.

We need to understand and respect how far we’ve come with this technology in months, not years. We are all in beta still — printers, dealers, manufactures, and software companies — with what DTF is.

DTF will continue to advance and stabilize, but it’s not going anywhere. It has shaken up apparel printing and will continue to do so. Those not on board with an in-house solution or a stable print provider will be left in the dust.