You may have seen direct-to-film printing pop up in recent years, but what exactly is it? And is it a fad orr is it as revolutionary as people say?
If you work in the custom printing business or like making personalized shirts, bags, or merch, you’ll know that not all printing methods are equal. For example, some work great on cotton but fail on polyester, while others require expensive setups that only make sense if you run a large operation. That’s why direct-to-film (DTF) printing is shaking things up – it’s easy to learn, has low overcost, and works on practically any fabric.
In this article, we’ll explain everything you need to know about how DTF works and how it can benefit your business.
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What is direct-to-film printing?
How does DTF printing work?
Step 1: Print your design on a special film
Step 2: Apply the adhesive powder
Step 3: Cure the powder with heat
Step 4: Transfer the design to the fabric
Step 5: Peel off the film
What can you print using DTF?
DTF printing on T-shirts and apparel
DTF on promotional products
DTF for custom patches and emblems
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What is direct-to-film printing?
Direct-to-film printing involves printing a design onto a special PET film before transferring it onto fabric using heat and an adhesive powder.
Unlike direct-to-garment (DTG) printing, in which ink is sprayed directly onto cloth, DTF allows you to print on a wider variety of materials beyond cotton, such as polyester, blends, nylon, and even leather. While its two-step process is more complicated than DTG printing, the trade-off is better durability, lower costs, and no need to pre-treat fabrics.
How does DTF printing work?
Here, we’ll walk through the entire DTF process so you can better understand what it entails:
Step 1: Print your design on a special film
First, the design is printed onto a clear PET film using a DTF printer. The print first lays down a white ink base so the colors don’t look faded on dark fabrics. Then, the desired colors are printed on top for a crisp and vibrant look (the white is only visible if the artwork has some white elements).
Step 2: Apply the adhesive powder
This part is where DTF gets interesting. Instead of ink being directly printed onto the fabric (like DTG), this process involves a special adhesive powder being applied to the printed film, acting as a bonding agent between the ink and the fabric and helping to hold the design after heat pressing.
Pro tip: The powder must be spread evenly over the design for the best results. If done by hand, any extra powder should be shaken off; otherwise, it may cause uneven bonding.
Step 3: Cure the powder with heat
Curing is the most important part of DTF printing, as this is when the adhesive is activated. This usually involves a heat press, curing oven, or conveyor dryer.
The goal is to melt the adhesive enough to make it sticky but not overly dry.
After curing, the film can be applied immediately, or it can be stored for later, making this technique perfect for bulk printing. This allows you to prep designs and transfer them when needed.
Step 4: Transfer the design to the fabric
To transfer the design onto fabric, the printed film is placed on the fabric and applied for about 15 seconds using a heat press at around 325°F, melting the adhesive and bonding the ink to the fabric’s fibers. After successfully transferring the design, wait for the fabric to cool. The process is now around 90% complete.
Step 5: Peel off the film
Once the fabric cools, the PET film is peeled off, hopefully revealing a vibrant, high-quality print. This is different from vinyl transfers, which sit on the fabric, in that DTF prints feel softer and are more flexible, meaning they won’t crack, peel, or fade easily.
What can you print using DTF?
While DTG is limited to cotton, and sublimacja only works on polyester, DTF prints on almost anything, including:
- Cotton and cotton blends
- Polyester and performance fabrics
- Denim, canvas, and leather
- Hats, bags, and even shoes
That’s huge if you’re looking to offer various custom products. Below, we dig into how it works in different applications.
DTF printing on T-shirts and apparel
DTF printing on T-shirts and apparel is one of its most flexible applications. It allows businesses to expand their product offerings without needing multiple methods. One major advantage is that DTF printing easily produces detailed, multi-color designs.
Unlike traditional techniques that require multiple steps, DTF can print complex, full-color images in one go. For this reason, it’s a great option for photorealistic prints, gradients, and designs with many color variations on T-shirts and other apparel, regardless of the material.
DTF on promotional products
DTF printing can bring bold, long-lasting designs to all products, from tote bags and hats to mousepads and phone cases. This versatility helps businesses maintain a consistent brand across different items, making their marketing more impactful.
But that’s not all. DTF printing can also enhance the appeal of promotional products with high-quality prints, making even simple items become attention-grabbing marketing tools. This added value will make promotional products more impactful and memorable for customers.
Even better, DTF printing looks amazing on non-flat surfaces. While some printing methods can handle curved or textured items, DTF adapts easily, making it perfect for water bottles, umbrellas, and golf balls.
DTF for custom patches and emblems
Want better custom patches and emblems? DTF printing can also make this process easier and more versatile. Forget traditional embroidered patches’ color limitations – DTF printing can create detailed, full-color designs, including gradients and photorealistic elements. This gives businesses, sports teams, and organizations more creative freedom to design bold and unique patches.
DTF prints will also resist fading and wear even after multiple washes. This keeps patches looking vibrant and professional over time. The result is a high-quality patch that offers the durability of traditional embroidery but with far more design possibilities.
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If you’re considering custom printing, DTF might be your best bet given it works on almost any fabric or material, provides prints that are high-quality and durable, does not require pre-treatment (unlike DTG), and it has lower setup costs than screen printing.
But the process is not without its downsides. For example, you must still invest in the right equipment, including a DTF printer, heat press, and adhesive powder. It’s also not as fast as screen printing for bulk orders (but is way better for small runs). And like any printing method, there’s a learning curve before you can maximize its potential.
Should you try DTF? If you’re looking for a cost-effective, durable, and versatile printing solution, it’s a solid choice and is likely here to stay.
