Garment and Apparel Print: The Ins and Outs of Garment Printing

Entering the world of garment and apparel printing can be daunting. With the choice of fabric, printing technology, and software solutions all being pivotal to achieving eye-catching designs with lasting durability, every choice plays a crucial role in shaping the final product.

With an increasing number of sign-makers choosing to offer direct-to-film (DTF) and direct-to-garment (DTG) options, we delve into this still-growing market, speaking to a range of experts in the field to provide advice for those wishing to expand into garment and apparel.

Time for Tech

Recent industry events such as FESPA Global Print Expo and The Print Show have seen a strong focus on garment printing technologies, with a number of major manufacturers bringing new products to the market.

As with any technology, it’s crucial that the software working in tandem with machines is up to speed.
The first hurdle of garment printing is creating a digital design suited for the fabric and the printing method. Different methods like DTG and DTF have unique requirements, influencing factors like colour resolution and detail.

For Bobby Grauf, head of business development (EMEA) for printing design software, Antigro Designer, it’s important to nail these factors before printing begins, to avoid re-runs and wasted resources.
“It’s crucial you get the basics right such as image quality and placement”, he explains, adding: “This includes image resolution, which should be at least 300dpi. As with other printed products, bleedlines – and in the case of garments, dyelines – also need to be considered to ensure parts of the design aren't missing.”

Grauf also points towards some of the digital design choices that can maximise efficiency. “When designing for garment printing, it’s a good idea to create vector designs (made up of lines and shapes rather than pixels), as this means the designs can be scaled depending on the size of the garment without losing quality.

“In DTF, maximising your transfer sheets and reducing waste is also important for printers’ margins and for the environment. Ganging designs together on DTF gang sheets allows printers to print multiple designs in one go.”

The Antigro Designer software has been developed to streamline these processes and decision points. The cloud-based print personalisation tool enables companies to offer editable templates to customers, with a wide range of personalisation options for any kind of printed product, including garment and apparel.

Its DTF Gang Sheet Builder tool automatically nests graphics and adjusts the size of a gang sheet, streamlining the file creation process and reducing manual intervention.

The product can be integrated with domain-specific APIs, generating print-ready files tailored to your exact print equipment. These features are designed to reduce errors, eliminate the need for time-consuming revision cycles, and speed up production.

Speaking about what Antigro can offer, Grauf says: “As a provider of innovative software solutions for personalisation and customisation in printing and e-commerce, we are well versed in developing specialised tools.

Our software is designed to streamline the various stages in print production, making customisation and personalisation accessible for anyone

“Our software is designed to streamline the various stages in print production, making customisation and personalisation accessible for anyone.”

Antigro is developing further software solutions this year, including a range of automation tools for printers.

Hinting at Antigro’s upcoming releases, Grauf says: “We are excited to add to our solutions for advanced customisation and AI-based automation in response to customer demand. Stay tuned for more information, especially if photobooks pique your interest.”

The Right Result

When deciding on a garment type for DTG or DTF printing, a range of factors must be carefully considered to achieve optimal results.

Firstly, the fabric composition plays a pivotal role. Natural fibres such as cotton tend to absorb ink better in DTG printing, resulting in vibrant colours and a softer feel. Conversely, synthetic fabrics like polyester might require specialised pre-treatments and inks for DTG, to ensure adhesion and vibrancy.

For DTF printing, the base material should ideally be compatible with the adhesive films used, typically polyester or poly-cotton blends, to ensure the film adheres properly and transfers cleanly.

For Sara Sanders-Smith of Result Clothing, there are three factors that are most important when choosing a garment to print on.

“For me, the key is longevity, value for money, and that the garment you choose, together with its decoration type, make the design look as good as possible.”

Continuing her advice to printers, Sanders-Smith says: “It’s important that the fabric has been properly constructed to take print, and to test that the media is suitable to use on it.

“They should also make sure that it sits at the price they are budgeting for, and that stock is available when they need it.”

Result provides the garment and apparel industry with versatile outerwear, headwear, and accessories, specifically tailored to allow for high quality prints.

But aside from garment quality, Result is also focusing on recyclability and reducing environmental impact in the time of ‘fast fashion’. According to a recent report by consulting firm, McKinsey, 70% of fashion brands are now actively seeking more sustainable printing methods.

Recent market innovations mean that eco-conscious options are now available to garment printers without the need to break the bank.

Sanders-Smith explains: “We no longer introduce anything new to our range that does not have a recycled element, and we are transitioning all our best-selling lines to using recycled fabrics.
“Improvements to the weave and feel of fabrics using recycled materials are the best and biggest innovations to our industry. Greater uptake of these fabrics means their price is now equal to virgin polyester fabrics, so we are able to price match or transition styles using these fabrics.

“Customers no longer have to feel bad – being price conscious now means you can also be environmentally conscious.”

A Direct Impact

DTF printing has been increasingly turned to by garment decorators looking for a versatile and durable option for bold garment designs. Those recommending the method point to the staying-power of DTF. The prints are designed to be resistant to cracking, peeling, and fading, allowing for designs that can last for many years.

Printers also point to the speed of DTF, as the process does not require pre-treatment of the garment.
When choosing the right DTF printer for the job, there are a wide range of factors that must be considered. For Colin Marsh, founder and managing director of Resolute DTF, choosing a durable printer with a strong reputation in the industry is of key importance.

“It’s important to choose a printer built with robust materials that has a solid performance track record”, Marsh says. “You should also make sure to ask how many active installations the product has in the UK. This ensures longevity and reduces the likelihood of frequent breakdowns or costly repairs.”

Resolute is a manufacturer of printers, inks, and related products for the DTF and garment market. Its printing solutions include the R-Jet PRO DTF V8i, which boasts speeds of up to 40m per hour in monochrome and 30m per hour for full-colour prints.

Marsh also highlights the choice of ink as key to nailing the perfect DTF print. “Make sure a good quality ink is supplied with traceability and the relevant certifications”, he says. “OEKO-TEX & HAPS certificates are essential, which demonstrate that the inks are free of hazardous air pollutants.”

As well as ensuring safety, Resolute focus on ease-of-use and quality when choosing inks and print heads. Marsh. explains: “Resolute is one of the few companies to offer an anti-clogging warranty on print heads. It doesn’t take a rocket scientist to work out that if you are buying a DTF printer and the print heads are not covered for clogging, that is not good.”

Marsh suggests using DuPont Artistri P1600 ink for its anti-clogging capabilities: “We find it jets better, meaning that the life of the print head will not be reduced by low quality components that degrade the components. Using a high-speed quality ink is worth every penny, as the print heads do not wear out and it can therefore extend the life of a print head.”

Resolute recently opened the only dedicated research and development facility for DTF in the UK, aiming to push the boundaries of what is possible within the field.

Speaking of the innovations to come from Resolute, Marsh says: “In 2025 we will be launching two new DTF processes offering brighter white prints, aiming to match or even beat traditional vinyls. Our Ultra DTF transfer system also launches this year, offering sportswear decorators transfers that block out stripes and combat dye sublimation.”

"It’s a 'YES' from Me"

For John-Paul Burton, managing director of YES Group (formerly known as Your Embroidery Services), adding garment options to your arsenal is all about increasing your versatility and customisation options for your customers.

Burton explains: “Many sign-makers are looking for diversification and versatility in order to stabilise their business or expand their market. For them, adding custom apparel to their business makes sense because most companies ordering signs also order custom t-shirts or polos at some point, especially for events. So, it’s a simple matter to increase your average sale and do that profitably.”

The Mansfield-based distributor of embroidery, DTF, and DTG solutions is celebrating its 30th year in business this year. It recently announced the addition of the Prestige R1 DTF printer to its product lineup. This new model is designed to offer a lower-cost solution for businesses seeking to expand their custom apparel production capabilities.

According to Burton, three core factors have driven a recent spike in DTF printer adoption by the signage industry in recent months.

“Firstly, compact roll-to-roll DTF printers are bringing the size and the costs firmly in the range of businesses that don’t do incredibly high volume or simply have space limitations”, he explains, adding: “The availability of space and capital isn’t the barrier to volume DTF printing that it once was.

“On top of this, built in fume extraction on the industrial side has made it easier to accommodate a wide variety of environments for the standard 24-inch and larger roll-to-roll DTF printers.

“Finally, printing onto sublimated shirts and jerseys with great results and print longevity is now possible thanks to the combination of inks, software, and printer settings from our digital HeatFX and ColDesi DTF printer line-ups.”

YES Group’s offerings include the Prestige R2 Pro DTF station, which YES recommends coupling with the new Miro 13 MAX shaker dryer. The R2’s advanced white ink circulation system is designed to prevents clogs and ensures consistent print quality, especially important for DTF printing.

But for Burton, DTF is not enough on its own, for those sign-makers wishing to move into providing garment offerings he suggests a combination of different garment printing options working in tandem will result in a more bespoke service for your clients.

As he puts it: “Fundamentally, offering more than one customisation method creates both market opportunities and contributes to some exclusivity. The ability to offer custom printed tees or promotional products to your sign customers gives you the potential to add revenues to every sale to those existing clients.

“Adding an embroidery machine or UV printer can add similar avenues to sales growth. But adding combinations of a DTF printed tee with a custom embroidered cap, left chest logo, small UV sign, or decal to an event package, boxes out the competition that can’t offer the same versatility.”

It’s Heating Up

Once your DTF design has been printed, you then need to consider how best to transfer it onto the garment.

Modern heat presses are designed to streamline this process, allowing any garment decorating business to quickly customise garments.

Manufacturer Stahls’ is regularly innovating within the heat transfer market. Its new Hottronix ProPlace IQ uses cloud-based technology, allowing the user to upload a transfer design which it then projects onto the garment before the design is pressed. This innovation gives you a heads-up on what the final design will look like and allows for accurate placement of the design before you print.

For Andy Rogers, marketing director for Stahls’ UK and Europe, the choice is obvious for sign-makers wishing to enter the garment market: “Do it, this is a great opportunity for sign-makers. Next time you visit a customer, take a look at how many of them are wearing branded apparel. One of your competitors could be supplying these.”

Rogers stresses that simply adding a heat press into your arsenal can enhance your product offerings, especially if you already use DTF printing for hard goods such as cups and phone cases.

He continues: “If you are already using DTF for printing onto hard goods, a heat press can be used alongside this or with your existing sign-making business. Get a heat press with an auto-open release, and you could include this into your existing workflow without hiring additional personnel. The press can sit next to the existing equipment and the industry standard for delivering transfer materials is two days maximum.”

In Rogers’ view, recent innovations in the heat press market allow for a wide variety of garment options, tailored to your customer’s exact desires.

“Focus on what the customer wants”, he says. “With the technology available with good quality heat presses and transfers, you can now decorate on 99% of fabrics. So let the customer pick their preferred option, then speak to Stahls’ and we will find a decorating solution.”

It’s No Fabrication

The garment printing sector is rapidly evolving, driven by advancements in printing technologies, software, and an expanding range of fabric options.

The evidence of growth in the market is clear to see, with a range of garment and apparel companies demonstrating expansion in response to increased demand. In the last few months, GoCustom Clothing has opened a new facility in Covent Garden, InkTec has continued its expansion with new a sales team, and T-Shirt & Sons has strengthened its arsenal of solutions with the installation of a Kornit Apollo garment press.

As the demand for personalised garment products grows, staying on top of market trends and innovations will be key for businesses looking to remain competitive in the market. To stand out from the crowd, you have to be cut from a different cloth.