M&R’S ADVANCES AND ADVANTAGES OF DTF PRINTING

Although direct-to-film (DTF) debuted in the early 2000s, it only transitioned from the hobbyist to the commercial print sector a few years ago. This was largely as a result of advancements in ink-delivery technology, innovation in consumables performance and improvements in hardware. It was also due to increased power of software, changes in consumer demand, diminished investment barrier and speed to competency.

As with all digital applications over the past two decades, printheads have continued to evolve and deliver better and better prints at continuously increased speeds. The unrelenting advancements in digital-print performance converted most print disciplines. However, the textile-printing sector was much slower to explore – and then accept – the potential advantages of digital technology. This was mostly as a result of the complexities, diversity and challenges inherent in achieving lasting, wearable and attractive prints. 

Until recently, most printhead manufacturers focused their attention on sectors that printed onto predictable substrates such as paper, vinyl, rigid and semi-rigid stock, with printhead-friendly inks. The debut of entry level direct-to-garment (DTG) printers in the 2000s catalysed research into improved solutions for addressing textile printing. 

Although it too started with the hobbyist sector, gradual advances were made into the commercial world. The acceptance of digitally printed textile, demand for shorter print runs and the desire to print onto non-cotton based fabrics, paved the way for DTF.

Printhead-manufacturing companies began to focus on textile applications. Epson was an early innovator and its i3200 printhead is the ’go-to’ DTF choice. M&R has also harnessed the capabilities of this printhead in its Quatro range of DTF printers. However, the printhead is only one link in the chain of success – albeit an important one. Without a harmonious ink-delivery sub-system, the printhead would be as useful as a car engine with a blocked fuel system. This sub-system needs to include tubing, filters, dampers, pumps, de-gassers, recirculation, printed circuit boards (PCBs) and capping systems.

The Quatro range of DTF printers is a manifestation of continued commitment

Advances in printhead technology would not be possible without advances in consumables. Although DTF film and powder are crucial in achieving a successful applied print, these are viewed as post-delivery consumables. Ink, however, is viewed as a delivery consumable and, as such, forms the foundation of future success. 

Ink manufacturers have concentrated on formulating inks that maximise performance through the printhead. In parallel, they have focused on achieving desired resolution, colour gamut, opacity, adhesion, light fastness, wash fastness and feel. Firstly, this combination of properties is extremely difficult to achieve. Secondly, it is tricky to produce consistently. Thirdly, it is challenging to maintain in diverse environments and freighting scenarios. 

M&R’s ink-manufacturing partner – Nazdar – has been able to achieve and excel at producing what its extensive customer base considers the best ink technology available. But this is a fluid market and evolving delivery technology requires a consumable collaborator that can keep abreast of change. M&R is confident that its platform-consumable partnership will keep pace with this rapidly changing decorating channel. M&R has also partnered with another leading company – Caldera – to provide a RIP solution tailored specifically to DTF printing.

Most industrial components have improved in performance, become smaller, lighter, more economical and available. Many new components and technologies have been introduced that have enabled the building of compact and affordable DTF systems. Access to these components and technologies has birthed a slew of DTF printer options. The vast majority of these are manufactured in China and often distributed through non-accountable channels. M&R has resisted the temptation of the full import-and-resupply model. The company has maintained its ethos of building long-lasting, high performance, robust and serviceable platforms. The Quatro range of DTF printers is a manifestation of continued commitment.

As with hardware, software and computer hardware has continued to increase in power, drop in price and offer possibilities now taken for granted. DTF has benefited from affordable RIP solutions that had previously been the domain of more expensive processes and systems, provided in collaboration with Caldera.

Over the past decade, print runs have become smaller and smaller as consumers demand fast fashion and bespoke expression. This has put pressure on traditional textile-decoration channels – most significantly screen printing – and opened up opportunities for digital channels. DTG was the first application technology to harness this opportunity and satisfy consumer expectations. However, soon consumers demanded digital expediency for decorating other substrates. DTG’s current ink-delivery limitations prevent it from decorating many substrates and items that are more readily accomplished with DTF prints. 

This diminished investment barrier is the most significant advantage DTF holds above all other decorating channels. Not only is it the least expensive decorating channel, compact, comparatively less demanding on power, movable, relatively easy to commission, but is also the most versatile. As with many purchases, low pricing is very tempting. However, inexpensive DTF printers are ideal examples of false economy. M&R has stayed the course and provided the Quatro – a safe, high quality, reliable, serviceable system backed by thorough documentation, development and training.

The learning curve is arguably the easiest of all the decorating channels. Although there are many aspects to consider in achieving a quality result, competency is more readily transferred than other decorating channels. Here M&R excels with in-person training, training classes and an online learning management system.

As with most decorating channels, M&R envisions greater focus on impactful imaging, faster output, increased automation, inline process co-ordination, AI-assisted workflow with QA/QC, eco-friendly consumables and upgradable solutions. M&R is well underway to pursuing many of these goals. While celebrating its 40th anniversary, the company launched the Quatro 68 at ISS Long Beach 2025. 
The Quatro 68 offers six printheads and eight colours (CMYK + red, green, orange and violet, in addition to white), the Cutter-X and Cutter-XY. See www.mrprint.com/equipment/quatro-direct-to-film-dtf-transfer-printing-system.