Expanding Screen Printing Capabilities with Direct-to-Film (DTF)

Screen printing is still the go-to for high-volume apparel decoration. But customer expectations have changed. Faster turnarounds, smaller quantities, personalization, and full-color artwork are now common requests.

Direct-to-Film (DTF) printing has become one of the most practical ways for screen print shops to meet those demands without disrupting what already works. DTF isn’t a replacement for screen printing. It’s a complementary method that helps shops say “yes” more often—especially for jobs that don’t make sense on press.

What Is DTF Printing?

DTF (Direct-to-Film) is a digital transfer process.

1. Artwork is printed onto a PET film using CMYK inks plus white.

2. While the ink is still wet, a hot-melt adhesive powder is applied to the printed areas.

3. The film is cured to set the adhesive (using a shaker/dryer unit, oven, or heat press).

4. The finished transfer is heat pressed onto a garment or substrate and the film is peeled hot or cold (depending on the system).

One of the biggest advantages is versatility. DTF works on cotton, blends, and synthetics, and it supports full-color, detailed designs without screen setup.

Why DTF Matters Right Now

DTF adoption has accelerated quickly because it delivers what buyers want: speed, flexibility, and low minimums.

For many shops, DTF helps relieve pressure from labor shortages, rising costs, and tighter timelines. Instead of tying up screen print production with small runs or complex art, DTF can handle those jobs efficiently while screen presses stay focused on volume.

Where DTF Fits in a Screen Printing Workflow

DTF integrates naturally into screen printing operations because the production mindset is already there—quality control, color awareness, and deadline-driven scheduling.

Here are a few common ways shops use DTF alongside screen printing:

1. Short runs and quick turns (no screens, less setup).

2. Full-color jobs without separations.

3. Overflow production when presses are booked.

4. Personalization like names, numbers, and custom elements without cutting vinyl.

DTF is especially useful for samples, reorders, and detailed designs—the types of orders that can slow down traditional screen print scheduling.

What You Need to Bring DTF In-House

A typical in-house DTF setup includes:

1. A DTF printer

2. A powder application + curing solution (often a shaker/dryer unit)

3. A heat press for applying transfers

4. Consumables: transfer film, adhesive powder, and inks

Most shops start lean, often with a single printer, and add capacity or backup equipment as volume grows. Space and power requirements are generally similar to other digital print equipment.

Environment matters too. DTF systems perform best in a clean, controlled area with moderate temperature and roughly 40–50% humidity. In screen printing environments, airborne fibers and dust can impact quality, so placing DTF equipment away from dryers and dusty zones helps reduce defects.

Getting Better Results: Artwork Prep and Consistency

High-quality transfers start with good files.

Many workflows begin with PNG or JPEG artwork with transparency. As shops move into more advanced RIP workflows, formats like EPS and PDF are also common. The file type matters less than the quality of the original artwork—resolution, clean edges, and overall design preparation will show in the final transfer.

Consistency is another major opportunity. Shops with strong screen print fundamentals often have an advantage because they already understand color matching, production discipline, and repeatability—especially important for customers who need brand consistency across multiple items.

How Shops Are Selling DTF (and Who’s Buying)

DTF isn’t limited to T-shirts. Many decorators use it for sportswear and promotional goods, which opens the door to new customers and new sales models.

One fast-growing option is selling transfers to other print shops. Many transfer sellers build online ordering around “gang sheets,” where customers upload multiple designs and arrange them efficiently on one sheet. Pricing is commonly based on sheet size or square inches, and fast turnaround becomes a key differentiator.

DTF is also a great fit for markets where personalization and quick changes matter:

1. Music festivals (small-batch merch and on-site customization)

2. Races and tournaments (names, numbers, finisher gear, last-minute changes)

3. Team sports and spirit wear (mid-season updates and full-color designs)

4. Recurring events (pre-made transfers for on-demand pressing with less waste)

5. Branded workwear and uniforms (small batches, customization, and fast replacements)

Real-World Impact: Why Shops Add DTF

A common theme from shops that add DTF is control—bringing more work in-house, reducing subcontracting, and handling complex, multicolor orders more efficiently.

Once DTF is dialed in, it often becomes the solution for jobs that used to be inconvenient, slow, or unprofitable with traditional screen printing alone.

Start Small, Grow Fast

For screen printers, DTF can be a strategic capability that expands what you can offer while protecting margins and improving responsiveness.

Key benefits often include:

1. Short-run efficiency (no screen setup, faster changeovers)

2. Reduced labor touchpoints

3. Expanded design flexibility (high-color and photographic artwork)

4. Faster delivery and more options for customers

5. Increased profitability on jobs you used to turn down

If you’re exploring DTF, a smart way to start is simple:

1. Identify the jobs you currently avoid or lose money on that DTF could handle profitably.

2. Choose equipment and consumables based on consistency, reliability, and support—not just price.

3. Build repeatable settings for film handling, curing, and heat press application through testing.

DTF isn’t just a trend. For many modern print shops, it’s becoming a core capability that helps them stay fast, flexible, and competitive.