Digital textile printing

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Digital textile printing is described as any ink jet based method of printing colorants onto fabric. Most notably, digital textile printing is referred to when identifying either printing smaller designs onto garments (T-shirts, dresses, promotional wear; abbreviated as DTG, which stands for Direct to garment printing) and printing larger designs onto large format rolls of textile. The latter is a growing trend in visual communication, where advertisement and corporate branding is printed onto polyester media. Examples are: flags, banners, signs, retail graphics.

Contents

Types of printing can be divided into:

Digital textile printing started in the late 1980s as a possible replacement for analog screen printing. With the development of a dye-sublimation printer in the early 1990s, it became possible to print with low energy sublimation inks and high energy disperse direct inks directly onto textile media, as opposed to print dye-sublimation inks on a transfer paper and, in a separate process using a heat press, transfer it to the fabric.

Within the digital textile printing for visual communication a division has to be made in:

Production requirements

The ‘textile market’ comprises many different applications and requirements. The intended use of the fabric is the most important starting point to identify exactly what's needed to produce a specific end-product. A ‘textile’ product may vary from natural yarns for garments, through to synthetic fibers for flags and banners. A textile product can be a wall mounted banner, a stand-alone pop-up banner, a beach flag, country flag or company flag. It can be a carpet, back-lit frame, curtain, room divider, building wrap, bed cover, a garment and much more.

The predominant textile media used in visual communication is a polyester based fabric. In the US, nylon is often used for flags. In northern Europe, polyspun material has been the choice of fabric for traditional flag printing. In today's market, a woven or knitted polyester is the de facto standard. This differs from the predominant coated vinyl or pvc media used in the sign and display industry. The production process needs to fit requirements for the type of ink: high energy sublimation (also known as disperse direct), low energy sublimation (dye-sub), acid, reactive and pigment. In turn, the type of ink chemistry needs to fit requirements for the media (such as polyester, nylon, cotton, silk). Based on the media and ink combination, the choice comes for infra-red fixation, heat-press sublimation or steaming. The structure of the fabric also needs attention, for example whether it is woven, non-woven or knitted.

Polyester fabric is printed mostly with dye-sub or disperse direct ink, although UV and solvent inks (including HP's latex formulation) can also be used. The great benefit of sublimation ink is the fact that the colorants will bond with the fibre during sublimation or fixation. The colours are ‘inside’ the media and don't stay within the coating and on top of the media, as it is the case with UV-curable formulations. Even latex inks on porous textiles can suffer from crocking issues or ‘rub-off’. Low energy sublimation ink is easier to print with, but has the disadvantage of colours fading faster; its UV resistance, or light-fastness, is less resistant than equivalents using high energy disperse direct ink. Dye-sub can also suffer from a ‘halo’ effect which results in less sharp images. The disperse direct ink is a ‘stronger’ ink than the dye-sub kind, and this is very important for outdoor use, such as for fence fabric, flags and banners: artwork will last longer.

Another benefit of aqueous-based sublimation ink is the absence of hazardous components as found in UV-curable, solvent and, even, in latex inks. When executed properly, direct to media printing with disperse ink is achievable on uncoated fabrics and offers maximum print-through; this is essential in applications viewed from both sides, such as with flag printing. As such, products can be sold at a higher margin, with a ‘green’ label and with a higher quality. Other media and ink combinations cannot allow this.

The biggest advantage of direct to media is drastically reduced waste. This method doesn't need printing on transfer paper first before calendering (or heat-pressing) it onto the media. Waste is both an economical and an ecological factor in print production. Print speed doesn't account for much if a large portion is being thrown away as waste due to incompatibility of media, ink, treatment or lack of know-how.

The qualities of the printed end product should fit the needs of the application. Longevity, fastness and hand properties are important. Post-processing is something to think about: is the printed material easily confectioned, applied or handled. Should it be washed or does it need a finish (e.g. fire retardant, water repellent). A washed textile no longer has coating or ink residues and will, therefore, have a better feel. Moreover, it will be less prone to stains and it will last longer. However, digital textile printing fabric will fade out with repeated washings, so it should be labeled as dry cleaning only, and the best way is washing by hand with cold water or using washing machine with gentle cycle and use mild detergent. [15]

An alternative which does not require expensive equipment and dyes is Inkjet Fabric Printing which uses a standard inkjet printer (e.g. HP, Epson, Canon, Lexmark) and specially treated, paper-backed fabric sheets. Inkjet fabric sheets are currently available in cotton, bamboo and silk on Amazon and other websites. The removable paper backing makes the fabric stiff enough to go through your inkjet printer. Once the ink is dry (1 hour to overnight for heavy ink coverage), simply remove the paper backing, follow the directions for a water dip to set the ink, let the fabric dry, and you are ready to sew.

Economics

As well as material concerns and application issues, economics come into play. Where the traditional textile print industry is accustomed to mass production with long-runs, the digital inkjet business mostly produces short-run non-textile products. This approach to digital textile printing is very different, and so is the expectation. Where sign-makers are familiar with a single process system, traditional textile printing is accustomed to several production steps. In the balance of the economics behind production needs, it is important to understand the entire production flow. An example lies with the choice of fixation equipment and the subsequent implication of energy and resource cost; for example, a steamer needs water and energy, and a calender needs to heat up and uses much energy and considerable amounts of paper.

Additionally, the impact on business by legislation and requests from customers with regard to environmentally friendly products, are increasingly becoming a factor.

Growth

In 2015, the industry is valued at approximately US$7.5billion globally. The worldwide digital textile printing market for garment, home décor and industrial applications is experiencing strong growth of around 34% CAGR to 2019. [16]

Related Research Articles

<span class="mw-page-title-main">Printer (computing)</span> Computer peripheral that prints text or graphics

In computing, a printer is a peripheral machine which makes a persistent representation of graphics or text, usually on paper. While most output is human-readable, bar code printers are an example of an expanded use for printers. Different types of printers include 3D printers, inkjet printers, laser printers, and thermal printers.

<span class="mw-page-title-main">Screen printing</span> Printing technique

Screen printing is a printing technique where a mesh is used to transfer ink onto a substrate, except in areas made impermeable to the ink by a blocking stencil. A blade or squeegee is moved across the screen to fill the open mesh apertures with ink, and a reverse stroke then causes the screen to touch the substrate momentarily along a line of contact. This causes the ink to wet the substrate and be pulled out of the mesh apertures as the screen springs back after the blade has passed. One colour is printed at a time, so several screens can be used to produce a multi-coloured image or design.

<span class="mw-page-title-main">Printmaking</span> Process of creating artworks by printing, normally on paper

Printmaking is the process of creating artworks by printing, normally on paper, but also on fabric, wood, metal, and other surfaces. "Traditional printmaking" normally covers only the process of creating prints using a hand processed technique, rather than a photographic reproduction of a visual artwork which would be printed using an electronic machine ; however, there is some cross-over between traditional and digital printmaking, including risograph.

<span class="mw-page-title-main">Inkjet printing</span> Type of computer printing

Inkjet printing is a type of computer printing that recreates a digital image by propelling droplets of ink onto paper and plastic substrates. Inkjet printers were the most commonly used type of printer in 2008, and range from small inexpensive consumer models to expensive professional machines. By 2019, laser printers outsold inkjet printers by nearly a 2:1 ratio, 9.6% vs 5.1% of all computer peripherals.As of 2023, sublimation printers have outsold inkjet printers by nearly a 2:1 ratio, accounting for 9.6% of all computer peripherals, compared to 5.1% for inkjet printers.

<span class="mw-page-title-main">Dye-sublimation printing</span> Digital printing technology with wide color range

Dye-sublimation printing is a term that covers several distinct digital computer printing techniques that involve using heat to transfer dye onto a substrate.

<span class="mw-page-title-main">T-shirt</span> Style of inexpensive fabric shirt

A T-shirt is a style of fabric shirt named after the T shape of its body and sleeves. Traditionally, it has short sleeves and a round neckline, known as a crew neck, which lacks a collar. T-shirts are generally made of stretchy, light, and inexpensive fabric and are easy to clean. The T-shirt evolved from undergarments used in the 19th century and, in the mid-20th century, transitioned from undergarments to general-use casual clothing.

<span class="mw-page-title-main">Thermal-transfer printing</span> Digital printing method

Thermal-transfer printing is a digital printing method in which material is applied to paper by melting a coating of ribbon so that it stays glued to the material on which the print is applied. It contrasts with direct thermal printing, where no ribbon is present in the process.

<span class="mw-page-title-main">Iron-on</span>

Iron-on transfers are images that can be imprinted on fabric. They are frequently used to print onto T-shirts.

<span class="mw-page-title-main">Wide-format printer</span> Computer-controlled printing machine

Wide format printers are generally accepted to be any computer-controlled printing machines (printers) that support a maximum print roll width of between 18 and 100 inches. Printers with capacities over 100 in wide are considered super-wide or grand format. Wide-format printers are used to print banners, posters, trade show graphics, wallpaper, murals, backlit film (duratrans), vehicle image wraps, electronic circuit schematics, architectural drawings, construction plans, backdrops for theatrical and media sets, and any other large format artwork or signage. Wide-format printers usually employ some variant of inkjet or toner-based technology to produce the printed image; and are more economical than other print methods such as screen printing for most short-run print projects, depending on print size, run length, and the type of substrate or print medium. Wide-format printers are usually designed for printing onto a roll of print media that feeds incrementally during the print process, rather than onto individual sheets.

<span class="mw-page-title-main">Textile printing</span> Method for applying patterns to cloth using printing techniques

Textile printing is the process of applying color to fabric in definite patterns or designs. In properly printed fabrics the colour is bonded with the fibre, so as to resist washing and friction. Textile printing is related to dyeing but in dyeing properly the whole fabric is uniformly covered with one colour, whereas in printing one or more colours are applied to it in certain parts only, and in sharply defined patterns.

Inkjet transfer or inkjet photo transfer is a technique to transfer a photograph or graphic, printed with an inkjet printer onto textiles, cups, CDs, glass and other surfaces.

Vinyl banners are a form of banners made of vinyl. The most commonly used material is PVC. Most banners are now digitally printed on large format inkjet printers which are capable of printing a full color outdoor billboard on a single piece of material. They are used for outdoor advertising.

<span class="mw-page-title-main">Transfer paper</span> Type of paper

Transfer paper is used in textiles and arts and crafts projects. Transfer paper is a thin piece of paper coated with wax and pigment. Often, an ink-jet or other printer is used to print the image on the transfer paper. A heat press can transfer the image onto clothing, canvas, or other surface. Transfer paper is used in creating iron-ons.

In streetwear fashion, an all over print is a print composed of a design that is repeated across the entire surface of a garment. The image is on both the front and back. Often, such prints are screen printed. Other processes include dye-diffusion of the fabric itself and printed t-shirts. All over printing relies on synthetic fibers as they can best withstand the process. One way to check for all over printing is to be sure the pattern or design can be seen on the seam, hem, and around zippers.

Direct-to-garment printing (DTG) is a process of printing on textiles using specialized aqueous ink jet technology. DTG printers typically have a platen designed to hold the garment in a fixed position, and the printer inks are jetted or sprayed onto the textile by the print head. DTG typically requires that the garment be pre-treated with a PTM or pre-treatment machine, allowing for the following:

<span class="mw-page-title-main">Mutoh Europe nv</span>

Mutoh Europe nv is a business unit of Mutoh Holdings Co. Ltd.

<span class="mw-page-title-main">Electronics for Imaging</span> American technology company

Electronics for Imaging, Inc. (EFI) is an international company based in Silicon Valley that specializes in digital printing technology. Formerly located in Foster City, California, the company is now based in Fremont. On July 1, 2015, EFI entered the textile printing marketing with the acquisition of Italian digital textile company Reggiani Macchine. On June 16, 2016, EFI acquired Optitex, a 3D digital workflow provider.

<span class="mw-page-title-main">Kornit Digital</span> Israeli printer manufacturer

Kornit Digital is an Israeli-American international manufacturing company. It produces high-speed industrial inkjet printers, and pigmented ink and chemical products for the garment and apparel, home goods, and textile accessories decorating industry. Kornit Digital has offices in Israel, Hong Kong, China, Germany and the USA. Ofer Ben Zur was Kornit CEO from its founding in 2002 until 2014, when he was succeeded by Gabi Seligsohn; Ben Zur remained as Chief Technology Officer. Ronen Samuel, formerly of HP Indigo, succeeded Seligsohn as CEO in June of 2018.

<span class="mw-page-title-main">Lumi (company)</span>

Lumi is a Los Angeles-based company founded by Jesse Genet and Stephan Ango that offers packaging and supply chain management software. The company got its start developing Inkodye, a photo-reactive vat dye that develops its color through exposure to UV or sunlight.

References

  1. 1 2 "atpcolor.it from google ( atpcolor textile printing ) result 1".
  2. 1 2 "rolanddga.com , rolanddg.com from google ( roland textile printing ) result 1 , 2".
  3. ↑ "eng.dgen.com from google ( d-gen textile printing ) result 1".
  4. ↑ "mimaki.com from google ( mimaki textile printing ) result 1".
  5. ↑ "mutoh.com from google ( mutoh textile printing ) result 1".
  6. 1 2 "atexco.com from google ( atexco ) result 1".
  7. ↑ "durstus.com , durst-group.com from google ( durst textile printing ) result 1 , 2".
  8. ↑ "hollanders-ps.nl from google ( hollanders textile printing ) result 1".
  9. ↑ "efi.com/products/inkjet-printing-and-proofing/vutek-superwide-printers/ from google ( vutek textile printing ) result 1".
  10. ↑ "kerajet.com from google ( kerajet textile printing ) result 1".
  11. ↑ "efi.com/products/inkjet-printing-and-proofing/reggiani-textile/reggiani-digital-industrial-printers/ from efi.com from google ( reggiani renoir digital printer ) result 1 from 'Reggiani Renoir digital printers, we are capable of printing any design flag (state, foreign or custom) at 110 linear yards per hour with acid inks on nylon fabric or disperse inks on polyester fabric' in annin.com/south-boston-virginia/ from google (usa flag maker factory) result 1".
  12. ↑ "msitaly.com from google ( ms textile printing ) result 1".
  13. ↑ "Digital textile printing machines – SPGPrints".
  14. ↑ "zimmer-austria.com from google ( zimmer textile printing ) result 1".
  15. ↑ "Frequently Asked Questions". Archived from the original on May 11, 2015. Retrieved April 25, 2015.
  16. ↑ "Digital Textile Printing Market to grow 34% in next four years". BanglaApparel.com. 6 September 2015. Retrieved 10 September 2015.


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