How to Set Up and Calibrate Your DTF Printer for Optimal Printing

Direct-to-film is a printing method that has been increasingly embraced in the 21 ^st century because, unlike other printing methods, it can handle both light and dark fabrics without compromising on quality. It involves printing designs on a special PET film and then transferring them to different substrates using pressure and heat. 

For this process, you need a DTF printer with special inkjet technology to handle the pigmented DTF inks. This article will guide you on how to set up and calibrate your DTF printer, how to calibrate DTF printer, and help you choose the right printer.

Using a DTF printer is not a trade-based skill, it can be learned overnight by anyone with the right instructions and equipment.

You start by being comfortable in your workspace. Set up your printer on a flat and sturdy surface. Any wobbling during printing will cause misalignments; you will also be preventing potential accidents with the printer toppling over. A good airflow is important since you will also be working with powders and heat which generates fumes. Also, check for a power supply and a proper storage area before unboxing and setting up the printer.

After unboxing the printer, inspect it for any damages or missing parts. The most important components you need to have are the power cord, the printer unit, the USB cable, the software driver package, the user manual, Ink bottles (CMYK + White), and the printhead cleaning kit.

If your printer is second-hand, it might not have some components such as a warranty agreement with the manufacturer. If any of these parts are missing, notify the manufacturer before setting up, because depending on the critical role of the part, the entire printer might be unusable.

Every DTF printer requires RIP software such as Acrorip, or EKPrint Studio, depending on the company. This Raser Image Processor helps manage the color profiles and layering white ink. Visit the official software website and download the latest version compatible with your operating system.

Some RIP software only works on Windows 10 or 11 and has no app or Mac versions. Others require a license key, so have that in hand in case you need it.

After downloading, run the installer and follow the installation prompts. If a driver CD is included, insert it in your computer then restart the operating system to load it. Installing the drivers and software should be done before you connect the computer to the printer.

DTF printers use CMYK and white ink which relatively have a thicker consistency compared to regular ink. This means that they are more likely to settle and clog the nozzles.

Use a syringe or funnel to fill the ink Cartridges.

Some printers have an automatic ink priming feature. They auto-check to ensure the inks are properly running through the printer’s tubing, dampers, and printhead before printing. If this feature is missing, you can do manual priming by performing a nozzle check, running a cleaning cycle, and mixing up the inks before printing.

If the ink is settled after a long printer downtime period, it does not necessarily mean that it has gone bad, just shake it to regain its consistency.

DTF printers print on a special PET film that is coated to ensure it properly holds the adhesive powder. Some of these films are single-sided coated, so you have to load them in the right way. The printable side should always face up on the printer’s loading tray.

After loading, it is time to adjust the printer settings on the RIP software to set up high-quality prints.

Calibrating a DTF printer, or any other printer, allows you to properly align the inkjet cartridge nozzles to the film you are printing on. Without calibration, your print quality might not meet your expectations. It also helps to maintain accuracy, standardization, and repeatability in measurements, which is a big deal, especially for printing businesses.

Before you start the calibration process, clean the printer and check that all the nozzle heads are unclogged, then fill up the ink tanks. If you haven’t used the printer in a while, prime the ink system to get rid of any air bubbles.

Think of this printing test as a diagnostic print that will help you identify any issues like poor ink distribution, printhead misalignment, or color inaccuracy. You will not be following similar steps as you would on a regular printing project because you don’t need to have a ready design to print.

You start by loading the PET film and then printing a nozzle check pattern. The nozzle check design has the most basic pattern with grids or lines with full-color representation, uniform density, and no missing parts, which makes it easy to detect errors.

You can find the nozzle check button either on the printer’s control panel or in software settings. If you are using the printer’s control panel, you can find this option under the “Maintenance” settings. If you are using the RIP software, it is under the “Printer’s settings”.

If the test print has gaps and missing lines, it means the nozzles are clogged. If the colors are faint, there are likely air bubbles in the system that deprive the nozzles of ink. A printhead misalignment will show through misaligned lines, and lastly, if your ink is contaminated, the lines will appear blurred, or the print smudged.

You can now adjust the printer settings to correct the diagnosis of the test pattern. You have to do a nozzle check after every setting you adjust.

Select “Auto Alignment” in the printhead settings or manually align the heads to your liking. The ink balance and color balance can be adjusted in the RIP software under the “Ink Management settings”.

Remember to set the resolution to 1440 dpi for high-quality prints. If you have detected ink pooling or banding, regulate the printing speed to either unidirectional or bidirectional to solve it. Lastly, adjust the “choke” settings to allow proper white ink under base spread that improves opacity on dark fabrics. The CMYK to White Ink Ratio should be balanced to avoid excessive white ink buildup.

With the adjustments in place, a final print check will confirm the success. You will later be using this print to perform a test transfer on fabric to check adherence to DTF powders, colors, edges, and vibrancy.

If you are satisfied with the results, don’t forget to save these settings on the RIP software so you don’t have to keep repeating this step in the future.

If you want to test the quality of the print check and the PET film further, transfer the design to a test fabric. To do this, apply adhesive powder on the film while the ink is still wet after printing, and cure with an open heat press at 160-170°C for 2 minutes. This melts the adhesive, creating a sticky surface.

Place the film on the fabric with the adhesive side facing down and press at 150-165°C for 15 seconds. Check on the quality of the transfer after peeling off the PET film, then make any adjustments, if needed, for your next design.

Since the heat press plays two major roles in DTF printing, you cannot afford to have one that does a shoddy job. Don’t be shy to invest in a high-quality heat press for consistent temperature and pressure application.

You can streamline your printing productivity and efficiency by using automation tools, especially if you are doing multiple printing jobs. You can invest in a DTF powder shaker and curing oven, and get automated RIP software. It automates color adjustments, ink management, and batch processing, so you don't have to make manual inputs every time. 

To make your job even faster and easier, arrange your printing, curing, and pressing stations in an optimized sequence for coordinating print jobs for belt-like DTF printing workflow.

Sometimes you might have everything else right, but end up with poor-quality prints or even damage to the equipment, all because the printer is incompatible. So, what type of printer do you need for dtf transfers?

You should not only have a DTF printer that is within your budget range but also one that is compatible with your needs.

To ensure you are making the right decision when buying a DTF printer, take into consideration the following factors.

DTF printers use specialized inks to achieve different results such as levels of color vibrancy, washability, and durability. The printheads determine the printer’s performance and print quality. Although most printers in the market have the Epson nozzle, you should check if it supports VSDT variable ink drop printing technology, can achieve 600 dpi ink jet accuracy, and also has a stable and long service life.

For commercial printing, speed should be your best friend. Check the printer’s production capacity and the number of prints it can handle in a given time frame. While at it, check the printer’s maximum print size to match your business needs. This should not compromise the print quality.

Some printers are unable to maintain consistent ink distribution at high speeds due to weaker motors, unstable printheads, inaccurate droplet control, or the inability to handle thick white ink layers properly. You can avoid these hardware limitations by investing in a quality printer.

There is a lot more you need to spend your money on after buying a DTF printer: PET film, the special inks, and maintenance, in addition to the initial cost. Although different models might offer the same features, performance and reliability, compare the prices and evaluate the value of each to get the best offer in the market and save the most you can.

If you are getting a DTF printer for your business, you might want to choose a roll-fed printer over a sheet-fed one. Unlike the latter, the roll-fed printer can print multiple designs continuously, improving production rates and serving a wide range of customers.