The DTF Column
Revolutionising DTF printing: Roll-to-roll to roll-to-sheet
DTF has progressed so far in the last few years; it is no wonder companies look to see if the limits on the technology can be pushed. In this column, Colin Marsh, managing director of Resolute, explains even newer trends coming from the technology.
D
irect to fi lm (DTF) printing has rapidly established itself as a transformative technology within the textile and garment decoration industry. Traditionally, roll-to-roll (R2R) systems have dominated DTF systems, offering high-volume production and continuous operation. However, as industry demands evolve and the need for smarter, more integrated workfl ows becomes apparent, a new trend is emerging, the transition from roll-to-roll to roll-to-sheet (R2S) systems. This shift, championed by market leaders Resolute, in partnership with Gildan, promises to elevate effi ciency, speed, and automation throughout the DTF workfl ow. With the concept of automated R2S starting back in January 2024, let’s take a look at where R2S is today.
The limitations of roll-to-roll DTF printing Roll-to-roll printing has been the backbone of DTF for its ability to process large volumes of fi lm effi ciently. Yet, this approach has some challenges over R2S systems. The continuous nature of R2R means that each stage, printing, curing, cutting, and handling, must be synchronised. Any delay, misalignment, or error can disrupt the entire process, wasting time or even worse, leading to reprints.
The emergence of roll-to-sheet systems Roll-to-sheet systems address many of the challenges associated with traditional R2R setups. In an R2S workfl ow,
A slitter breaking two images up, ready for robotic application
the printed fi lm is automatically cut into individual sheets immediately after printing and before curing or powder application. These sheets are then processed independently, allowing for greater fl exibility and precision at every stage. This automated modular approach not only streamlines the workfl ow but also enables the integration of advanced automation technologies, such as AI-driven quality control and tracking systems.
Key advantages of R2S
One of the primary drivers behind the shift to roll-to-sheet systems is improved effi ciency. By decoupling the print and curing process, R2S allows for parallel operations, while one sheet is being cured, another can be printed, and yet another can be prepared for pressing, all automatically with no operator intervention. When you look at the fl exibility of sheets over a roll, the fl exibility soon becomes clear. This multi-threaded workfl ow signifi cantly boosts throughput and minimises bottlenecks. Speed is further enhanced by the elimination of manual collation. Automated sheet handling reduces the risk of human error, accelerates job changeovers, and enables rapid adaptation to varying order sizes and designs. For high-mix, low-volume production (one-off web orders), an increasingly common scenario in the era of customisation, these attributes are invaluable.
Optimising the curing process
Curing is a critical step in DTF printing, as it ensures the durability and wash fastness of the printed image. In roll-to-roll systems, maintaining consistent curing across the entire length of the roll can be challenging; speed and environmental conditions play a big part in this process. With roll-to-sheet, each sheet can be cured under optimised and uniform conditions, offering consistent quality and reducing the likelihood of variation. More economical roll sizes can be run to eliminate waste. The most common heat press size, being 40x50cm, does not require any more than a roll width of 60cm; this includes multiple QR codes, quality check colour bars, printed in the out-of-image areas attached by a perforated tear-off.
Moreover, the nature of sheets allows for the implementation of smart curing tunnels that automatically adjust parameters based on the sheet’s characteristics, such as ink type, adhesive powder type and fi lm type, further enhancing the reliability and effi ciency of the process.
Templated roll-to-sheets and the power of QR codes These new innovative systems take the R2S concept a step
| 48 | October 2025
www.printwearandpromotion.co.uk
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