As someone who spent more than 20 years working in Formula 1 and medical device manufacturing, I am obsessed with attention to detail and the need for ultra-consistency in products. This obsession, along with meeting similarly like-minded Dae Ha Korea in 2012, has pushed me to gain a better understanding of the film used in direct-to-film (DTF) printing and, in particular, its impact on dot gain.
Dot gain is when ink dots spread beyond their intended size, blending into adjacent areas, softening the image and muddying colours. High, or uncontrolled, dot gain is typically when the dot spreads to more than 15% or more of its intended size. Pin-sharp designs turn into underwhelming prints as fine lines merge and edges blur. This results in reprints and wasted materials. Managing dot gain is crucial, then, for sharp, vibrant results.
Beyond aesthetics, high dot gain significantly impacts durability and ink usage. To compensate for faded colours, printers may increase ink volume, leading to higher ink usage. Over-saturation destabilises adhesion, requiring more powder and amplifying waste. Plus, even in DTF films marketed with claims of 50+ washes, excessive dot spread weakens the bond between ink, adhesive powder and fabric, making transfers susceptible to cracking or peeling, potentially resulting in fewer than the advertised number of washes.
In DTF printing, ink is jetted onto a print-receptive film. Hot melt adhesive powder is then applied and the film is cured in an oven before the design is heat pressed onto the substrate. Dot gain can happen during ink deposition, powder application, or heat pressing.
The single component responsible for carrying (and depositing) the inkjet droplets throughout this entire process – from print head to the garment – is the film. Therefore, using precision-manufactured films and coatings that control dot gain is paramount if you are seeking the sharpest image definition, truest colour reproduction, and most consistent results.
An advanced formulated, precision-coated film maintains precise dot placement, enhancing not only the look of the final print, but also its durability and ink efficiency.
To be even more specific, it is the film’s coating that is key to controlling dot gain. Typically, the coating will comprise a blend of polymers, such as acrylics or polyurethanes. This formulation dictates how well the printed ink will adhere, absorb, and dry on the film.
The coating’s pores, the tiny openings regulating ink absorption, are the secret to success. If the pores on the surface of the coating are larger than five to 10 microns, this will allow excessive ink to spread, causing all colours to bleed and blend. In addition, if the coating’s porosity is uneven, or there is high surface tension, the ink will wick outwards, amplifying dot gain.
Good quality DTF film coatings are created using advanced formulations to keep dots compact, ensuring even ink distribution and producing pin-sharp detail and colour accuracy.
Coating consistency is also vital for achieving low dot gain across all colours. Even minor variations between film batches can lead to unpredictable results, with one roll delivering sharp prints and the next producing blurred images across the colour spectrum.
This highlights the paramount importance of using precision coating facilities in the manufacture of DTF film in order to consistently achieve uniform performance and colour accuracy. Precision coating facilities apply the formulation with micron level accuracy. They use laser thickness gauges and automated mixing to maintain uniformity within 0.1%, while stable materials and Class 1,000 Clean Rooms prevent deviations, ensuring consistent rolls, batch after batch.
This approach optimises porosity and surface tension, preventing dot expansion under heat. The results are life-like transfers with pin-sharp edges and vibrant colours that rival screen printing.
By using precision-coated film, optimising ink and printer settings for the film, adjusting RIP software for dot gain compensation, and carefully controlling the transfer process, DTF print shops can take control over dot gain and the quality and durability of their customers’ prints.
In today’s ultra-competitive DTF market, excelling in precise and consistent dot control is essential. As customers demand more intricate, pin-sharp and colour-rich designs, films that provide consistent low dot gain will lead the way. It’s this knowledge that fuels our push at Dae Ha UK to deliver transfers that exceed expectation. We know that DTF’s future lies in mastering these details.
Source: Images Magazine, September 2025, p.55 — Article by Michael Overy (Dae Ha UK)
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