If you’re a custom apparel designer, you have several printing technologies to choose from, including screen printing, sublimation printing, direct-to-garment (DTG) printing, and direct-to-film (DTF) printing.
Choosing the right printing process can make or break your custom apparel business. This guide breaks down the DTF printing process, how it compares to other popular printing techniques, and the pros and cons to help you make an informed decision.
What is direct-to-film printing?
Direct-to-film (DTF) printing is a heat transfer method where a design is first printed onto a special polyethylene terephthalate (PET) film. The film is coated with white ink and adhesive powder, then pressed onto the garment using a heat press machine. The heat and pressure activate the adhesive, permanently bonding the design to the fabric.
DTF printing technology is favored for its professional results, durability, and cost-effectiveness. The white ink base makes DTF printing an excellent choice for printing vibrant colors on dark fabric, unlike methods where ink soaks directly into the fabric.
You can get DTF printing services at a wide array of companies, including custom apparel shops, print-on-demand companies, commercial textile manufacturers, and local print shops.
What goes into direct-to-film printing?
Here are the primary steps that go into the DTF printing process:
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Prepare the design. Import the design and process it through Raster Image Processing (RIP) software, like Onyx, EFI Fiery, or Wasatch SoftRIP.
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Print on PET film. Print the design on PET film using a DTF printer equipped with CMYK (cyan, magenta, yellow, key/black) and white inks.
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Apply adhesive powder. Apply a layer of powder evenly to the printed film while the ink is still wet.
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Cure the film. Heat the film in a curing oven to melt the adhesive, preparing it for transfer.
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Transfer the design. Place the cured film on the garment and press it with a heat press.
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Peel off the film. Remove the film once the garment has cooled.
Direct-to-film printing vs. other printing methods
- Direct-to-film printing vs. screen printing
- Direct-to-film printing vs. sublimation printing
- Direct-to-film printing vs. direct-to-garment printing
Several alternatives to DTF printing exist in the custom design printing industry. Depending on your fabric and design, some options work better than others. Here’s how DTF printing compares to other popular printing methods:
Direct-to-film printing vs. screen printing
Screen printing is one of the oldest commercial fabric printing techniques. It uses physical stencils (screens) for each color, pushing ink through them onto the garment. Complex designs require more stencil layers, making the process more involved. A complicated design might have the following:
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Many different colors. Each color typically requires its own stencil, and with intricate designs, the overlapping layers can result in a print that feels thick.
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Intricate patterns or small details. These may require precise layering or specialized screens.
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Gradients, shading, or fine lines. These typically need extra steps or special screens to accurately reproduce.
On the other hand, DTF printing achieves an even application, regardless of how many colors or design elements you add.
Screen printing becomes much more cost-effective than DTF printing for bulk orders, typically 100 items or more, making it a great choice for mass production projects.
Direct-to-film printing vs. sublimation printing
Sublimation printing uses heat and pressure to turn ink into gas, which penetrates the fabric and leaves a permanent imprint. Unlike DTF and screen printing, where color sits on the surface, sublimation embeds into the fabric. This results in long-lasting prints that resist cracking.
Sublimation printing only works on polyester, which makes it popular for sportswear, but limits its applications. DTF printing, however, is compatible with a wide array of materials, including cotton, denim, silk, and polyester.
Direct-to-film printing vs. direct-to-garment printing
Direct-to-garment printing applies ink directly onto the fabric, much like a home or office printer applies ink to paper. It works best with 100% cotton fabrics, and often requires pre-treated garments to help the ink adhere properly and maintain vibrant colors.
Like sublimation printing, the ink in direct-to-garment printing soaks directly into the fabric, creating a soft print that feels like part of the fabric. DTG printing uses water-based inks which makes it more eco-friendly than DTF printing methods. Over time, its colors may fade naturally, giving the garment a worn-in, organic feel. DTF printing, in contrast, can be used on a wider variety of textiles, and produces designs that stay bold and vibrant for years.
Pros and cons of direct-to-film printing
Like all printing methods, direct-to-film printing has its pros and cons. Here’s how they stack up:
Pros
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Versatility. Works on numerous fabrics, including cotton, polyester, nylon, silk, and both light and dark textiles.
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Quick setup. Unlike DTG and screen printing, DTF printing doesn’t require pre-treatment processes or screen setups, saving time and labor.
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Print quality. Produces vivid colors even on dark garments.
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Durability. Withstands multiple washes without fading or cracking.
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Cost-effectiveness. Cost-effective for small or medium orders, generally under 100 items, since it requires minimal setup.
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Cons
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Adhesive powders. Can be messy and require careful handling to avoid damaging equipment.
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Specialized materials. The use of special films and adhesive powders can lead to higher setup costs compared to other methods.
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Fume ventilation. Adhesive powders release fumes when heated. Proper ventilation is essential.
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Print texture and feel. Creates a firmer texture than other methods, such as sublimation and DTG printing.
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Environmental considerations. PET films and adhesive powders are non-biodegradable, making DTF printing less appealing to eco-conscious customers.
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Maintenance and technical expertise. DTF printers and heat presses require regular maintenance to prevent issues like clogged nozzles or inconsistent print quality.
Direct-to-film printing FAQ
Is direct-to-film printing good quality?
Yes, DTF printing produces high-quality designs. It uses durable inks that hold up well to frequent washing. The white base makes it particularly effective for printing on darker garments and helps colors pop across different materials.
What does direct-to-film print mean?
Direct-to-film printing is a printing process where a design is first printed onto a special DTF transfer film, covered with adhesive powder, and then transferred to a garment using a heat press. Unlike sublimation or direct-to-garment printing, the ink sits on top of the garment, rather than penetrating the fabric.
How much does direct-to-film printing cost?
The cost of DTF printing varies depending on order size, design complexity, and whether you’re printing in-house or using a service. On average, small runs typically cost $1 to $5 per garment.
