What Is DTG Printing?
Direct to garment (DTG) printing is the most recent breakthrough for printing on fabrics in small or big quantities, with the benefit of achieving any number of colors and no repetition size limits. Direct-to-garment printing, often known as digital printing, has revolutionized the capacity to produce colorful images and complex designs fast and economically. This is why it is often used for custom tees, samples, and short runs. Screen printing involves a complicated procedure because of things like color separation, setup time, and the number of colors needed. Additionally, it can be expensive and time-consuming to incorporate photographic graphics onto fabric. Direct to Garment (DTG) printing, on the other hand, provides a quick and economical alternative by printing the artwork file directly onto the clothing using inkjet technology, similar to a typical paper printer found in homes or workplaces. For photo-heavy or multi-color designs, it removes the screen setup step that slows conventional printing. Garments inspection, pre-treatment, printing, post-treatment, and final inspection are all part of the work process.
DTG Printing History
In the 1980s, the garment industry began to use all-over printing. While roller printing was formerly prominent, flatbed and rotary screen printing techniques have since gained popularity. People’s tastes and requirements have altered with the passage of time, especially among the younger generation, who are particularly sensible of their clothes and decisions regarding fashion. As a result, global demand for all-over printing is continuously expanding, especially in Bangladesh. That demand is also driven by sample rooms and on-demand production, where low minimum order quantity matters more than long screen runs.
All-over prints are used on a variety of goods, including t-shirts, shirts, jeans, three-piece suits, and bed linens. However, screen printing processes for all-over graphics have stipulations. Flatbed or rotary screen printing cannot support all forms of patterns, and due to high printing costs and equipment complexity, each extra color adds another screen and registration step, according to M&R’s screen-printing guidance. Furthermore, screen printing is ineffective to highlight photo prints and 3D effects. To overcome these issues, the printing industry has developed a new method known as Digital Textile Printing or Direct-to-garment (DTG) printing. Digital textile printing became practical much later, when inkjet head quality, textile inks, and RIP software were good enough for repeatable garment production.
Direct-to-garment (DTG) printing, often known as Digital Textile Printing is a process that embosses bright graphics on a variety of materials, most often the garments, using digital ink-jet printing technology. The image is printed directly onto the fabric surface, so pretreatment and curing matter more than they do in many other print methods. It allows for the simple and exact printing of any pattern on garments, making it a very promising innovation in the textile sector. DTG printing does away with the requirement for screens and eliminates color limits. Furthermore, it is ideal for printing 3D creations. This approach enables for direct printing on garments such as t-shirts, shirts, and jeans while keeping design quality. In practice, DTG works best on 100% cotton or high-cotton blends, and it is less forgiving on synthetics unless the ink system is made for them.
DTG Printing Process Steps
The complete Direct to Garment (DTG) printing process on T-Shirt mainly involves 3 steps: The three things that decide the final result most often are file quality, pretreatment consistency, and curing temperature.
A. Pre Printing Steps
Pre-printing process is like preparation for the upcoming procedure, before you paint. It helps the process for adhere better to the t-shirt or other garment. You can print without pretreatment, but it negatively impacts the vividness of the print and the washability. On dark garments, skipping pretreatment usually makes the white underbase look weak and patchy. It can be categorized by the following steps:
1. Design Receive:
The Purchaser provides the design at first. The accuracy of the information provided is then confirmed through a careful analysis. At this stage, artwork size, background transparency, and print position should be confirmed before the RIP file is made. After that, the design is discussed at a technical meeting, and any issues are brought up with the merchandiser or buyer.
2. Design Development:
Preparing the Design for DTG: The designer creates the design based on the specifications provided. A clean DTG file should be high resolution, because low-resolution artwork usually looks soft after curing. We are able to modify the design to meet particular requirements and also offer our own concepts and ideas to fit the needs and themes of the customers.
Design Transfer from RIP Station to Operating Panel: Using Caldera or other software, the image files meant for printing are transmitted to an external Raster Image Processor (RIP) server. The RIP station separates the colors, and then the operational panel receives the image from the RIP server. The RIP file also helps manage white ink layers and color balance, so the on-screen image may look slightly different from the cured print.
3. Garment pre treatment:
A pre-treatment process is carried out using the proper chemicals to ensure successful printing on the garments. By doing this, the print is preserved during successive washings. Even spray coverage matters more than heavy spray volume, because uneven pretreatment often causes dull spots after pressing. The garment is carefully stored in a poly material after pre-treatment is finished to shield it from wind and moisture. There are 2 ways to apply Pretreatment for garments: Whichever method is used, the aim is an even film, not a soaked fabric.
Hand Spraying: For manual pretreating, the use of the sprayer to spray the garment as evenly as possible using a smooth back-and-forth motion. This works for small lots, but it needs practice to avoid overspray on seams and sleeves.
Pre-treatment Machine: Various automatic pretreatment device is now available. This is usually the more consistent option for repeated styles. With the help of this equipment, it is possible to precisely manage how much pre-treat chemical is sprayed, resulting in an efficient and reliable process every time. Simply put the garment on the tray, make any necessary adjustments to the pretreatment area, and press a button to start the pretreatment solution spraying onto the cloth. Use a scraping instrument to distribute the pre-treatment liquid uniformly across the fabric’s surface. Finally, use a heat press machine with a fixed temperature of approximately 160°C to 170°C, according to Epson’s current DTG curing guidance, to dry the pretreated clothing for 1-2 minutes.
B. Printing Steps
- Garment Loading: The pre-treated garment is loaded to the entry side of the machine. Before loading the garment on entry side, all necessary parameter must be cleaned properly. A lint roller is often used here, especially on dark cotton, because loose fibers show up clearly in DTG prints. Place the garment on the printer plate evenly without any wrinkle. During printing all sensor adjustment must be done. Platen height should be checked before printing, because even a small mismatch can blur the edges or leave platen marks. When we load garment on printer plate, the tension unit monitor is used. Garment on printer plate must be even for avoiding crush and print smooth.
- Select Image/Design and Print: To enable proper printing, Direct-To-Garment (DTG) printers frequently need specialized software called a Raster Image Processor (RIP). With the use of this program, any image or complex design may be printed precisely. Choose the image you want to print first. The best file is usually a clean high-resolution image with the correct print size and a transparent background. Next, decide on the area’s precise dimensions and shape so that the design can be printed there. In order to establish the price of the garment, you can also figure out the color settings and the cost of the printing ink. Ink coverage also affects cost, because large solid areas use more ink than fine line work. Press the print button once the image has been properly set up. You will access the printer control software as the print identifier, choose the file, and start the printing procedure by clicking the start button. A settings sheet for each fabric type is worth keeping on the machine, because it cuts trial prints and keeps output consistent.
C. Post Printing Steps
To set the inks and improve washability when the printing process is finished, the garment must be cured. The typical drying time is 1-2 minutes at approximately 160°C to 170°C, according to Epson’s current DTG curing guidance,. However, certain clothing may be able to cure at somewhat greater temperatures for a shorter period of time. Over-curing can make the print feel stiff, so time and temperature should be balanced rather than pushed higher for safety. Let the print cool flat before folding or packing, because trapped heat can affect hand feel and stacking.
DTG Printing Pros and Cons
| Pros | CONS |
|---|---|
| Fast turn around time for small orders. | Not cost effective for larger runs. |
| Easily print tons of colors; Great for photos. | Slow printing time per shirt. |
| Cost-effective for smaller runs. | Not available on all colors or materials. |
| Reduced manpower. | Limited design placement. |
| Nickle free. | Lack of efficient manpower. |
| Lower water and power consumption. | Print cost is very high. But it is reducing day by day. In small lots and sampling DTG is far convenient and cost effective than conventional forms. |
| Less Chemical waste. | The problem of the combination in new and old technology. |
| Large repeat size is possible. | Difficult to get high color yield if don’t use the suitable coating chemical and if the steaming is not perfect. |
| Reduced production space requirements. | Different fabrics behaves differently to the colors of inks; hence, color changes are there in digital print, despite the digital print file being the same. |
| Less printed inventory. | Poor fatigue properties. |
| Sampling and production done on same printer. | All types of garment can be print except blended. |
| Design innovation. | Need to maintain temperature and humidity for print unit. |
The note on blended fabrics is too absolute in practice, because many cotton-poly blends can still be printed successfully when the pretreatment and ink system are matched to the fabric.
DTG Printing vs Screen Printing
| DTG Printing | Screen Printing |
|---|---|
| DTG printing is the best option on a limited number of clothes, usually for short-run and on-demand orders, according to Printful’s DTG guide. The exact break-even point still depends on ink coverage, garment color, and labor time. | Screen printing is suitable for large number of production. |
| Due to the time required to print each t-shirt and the increased manufacturing costs, it might not be the best option for large volumes. | Time requirement is less in perspective of DTG printing, so it might be best option for large volumes. |
| DTG is the best choice since it enables for the printing of endless colors, which is great if your objective is to produce an intricate image or obtain photographic quality. That advantage matters most when artwork has gradients, skin tones, or photo detail. | In contrast, screen printing needs a different screen for every desired hue. That is why each extra color adds another screen and registration step, according to M&R’s screen-printing guidance, and there is no fixed universal color ceiling. |
| DTG uses thinner ink, which enables the development of more complex graphics. | The vibrant inks used in screen printing. |
| It works particularly well on light-colored materials. | Mostly suitable for deep-colored materials. |
| Additionally, DTG’s usage of water-based inks results in a more environmental friendly process. | Screen printing is not a environmental friendly process. |
| For optimal results in DTG printing, garments with a composition of over 50% cotton are recommended. The liquid ink used in DTG printers can be repelled by other materials like polyester. As a result, DTG printing works best on 100% cotton clothing. High-cotton blends can still print well when the pretreatment and ink system are matched properly, so blend fabrics should be tested rather than dismissed outright. | Screen printing is suitable for all types of clothing specially for blended. |
| Less Chemical waste. | More chemical waste in perspective of DTG printing. |
| More innovative design can be put on DTG printer. | Basically conventional printing process. |
| Lower water and power consumption. | Water and power consumption is more. |
| Sampling and production done on same printer. That is one reason DTG is widely used in sample rooms and small custom shops. |
DTG is strongest when you need detail, flexibility, and short-run speed on cotton-rich garments. For small custom orders, it is one of the most practical printing methods in day-to-day production.
References
- https://www.sciencedirect.com/science/article/abs/pii/B9780857094339500109
- https://www.emerald.com/insight/content/doi/10.1108/JFMM-03-2020-0053/full/html
- Epson DTG curing guidance
- Printful DTG guide
- M&R screen-printing guidance
Frequently Asked Questions (FAQs)
Q1. What fabric is best for DTG printing?
Ans: DTG printing usually works best on 100% cotton or high-cotton blends. Cotton absorbs the ink better, so the print looks sharper and lasts longer after washing.
Q2. Can DTG printing work on dark shirts?
Ans: Yes, but dark shirts usually need pretreatment and a white ink underbase. Without that layer, colors can look flat and the shirt color can show through.
Q3. Is DTG printing durable?
Ans: Yes, when the garment is pretreated well and cured correctly. Poor curing is the main reason DTG prints fade, crack, or wash out too quickly.
Q4. Do you need pretreatment for DTG printing?
Ans: Yes, pretreatment is needed for most DTG jobs, especially on dark garments. It helps the ink sit on the fabric instead of sinking in, which improves color brightness and wash durability.
Q5. Can DTG print on polyester or blended shirts?
Ans: It can print on some blends, but results depend on the fabric ratio, pretreatment, and ink system. Pure polyester is usually better handled by sublimation or another method made for synthetics.
Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. Mr. Kiron is working as a textile consultant in several local and international companies. He is also a contributor to Wikipedia.
