A modern multi-stage digital printing process where designs are printed onto specialized PET film, coated with hot-melt TPU powder, and heat-pressed onto garments.
DTF (Direct to Film) printing has transformed custom apparel manufacturing, particularly within the print-on-demand and streetwear dropshipping space. The process utilizes specialized wide-format digital inkjet printers equipped with stretch-resistant textile pigment inks in CMYK color channels, plus an ultra-opaque titanium dioxide white ink channel. First, the design is printed in reverse onto a translucent PET (Polyethylene Terephthalate) transfer film. Immediately after printing, while the ink is still wet, the film passes through an automated unit that applies an even layer of hot-melt Thermoplastic Polyurethane (TPU) adhesive powder. The film then enters an inline curing oven heated to roughly 110°C to 130°C, melting the TPU powder into a solid, flexible adhesive backing. Finally, the cured transfer film is aligned on a garment and heat-pressed using industrial pneumatic presses at 150°C to 160°C under 4-5 bar of high pressure for 10-15 seconds. Once cooled or warmed (depending on the film type), the PET carrier sheet is peeled away, leaving a highly vibrant, stretchable, and incredibly durable graphic print. DTF is highly prized because it works flawlessly across cotton, polyester, poly-blends, and nylon without complex pre-treatment, offering superior stretch-recovery and wash resilience compared to vinyl cutting or traditional screen printing.