Photo courtesy of Cessna Aircraft Company, Wichita, Kan.  Photo courtesy Tex Visions

WHY DIRECT-PRINTABLE FABRICS?
Today’s digital printing market is increasingly competitive, and when you just don’t have the time to waste on extra steps, you need a simplified process that still produces high-quality results. Textile printing, for example, is one of those applications that once required several steps to complete. But that is changing with the rise of direct-printable fabrics, which has seen much growth over the past few years and has many uses in the signage industry. 

In traditional dye sublimation fabric printing, you first print a reverse image of the graphic onto transfer paper and then run both the textile and paper through a heat press, says Scott Fisher, vice president of sales and marketing for Fisher Textiles. Once the fabric is removed, the image has sublimated from the paper to the fabric and is permanent. But with direct-printable fabrics, the need for transfer paper and a heat press is eliminated.  

“Direct printing technology takes a cumbersome step out of the printing process, and wherever a step can be omitted and time can be saved, it is so valuable to the print provider,” says Dwight Bessette, director of product development for Ultraflex Systems.

Even with fewer steps and a faster turnaround, there is no drop off in print quality, which often happens when the process is simplified, Bessette continues. 

Without that extra step, Jeff Leto, director of product management for LexJet, estimates you can cut production time by 30 to 40 percent. Now, instead of dedicating two employees to a single job, one can operate the direct-to-fabric printer, while the other takes on different projects. Eliminating the heat press process also protects your bottom line, Bessette says, as there is no need to purchase transfer paper and additional supplies.

Fisher further mentions that direct-printable fabrics add a green element to your printing approach. Without the use of transfer paper, your facility’s waste is reduced. 

“You’re taking away a consumable because there’s no need for the paper when it’s directly printed, so there’s a slight advantage when you look at the green factor,” Fisher explains. 

Tim Gallagher, president of Aberdeen Fabrics, believes another popular advantage of direct-printable fabrics is its spacious accommodations. There is no need for an extra heat press or washing machines—just one compact unit is all it takes. 

“You have white fabric in the back of the printer, then the printed fabric comes out of the other end, and it’s ready to go,” Gallagher says. “You don’t have to wash them; no other processes are required.” 

One direct-to-fabric unit, measuring front to back, is approximately 7 or 8 feet, and about 10 feet wide, depending on the width of the printer. With more available space, smaller shops have room to add other pieces of equipment that can diversify their product lines, Gallagher says. 

Flags, banners, trade show exhibits and P.O.P. displays are all popular textile applications and well-suited for direct-printable fabrics. This trade show display uses Ultraflex Systems’ UltraPoplin. Photo courtesy of Ultraflex Systems.

MAJOR INK PLAYERS

When working with direct-printable fabrics, there are four types of commonly used inks: solvent, UV-curable, aqueous and dye sublimation. Solvent, UV-curable and aqueous inks are used similarly, but dye sublimation ink differs. 

Typically, dye sublimation ink produces first-rate, photographic images, Leto says, because the process actually embeds the graphic into the fibers of the textile. However, the other inks have a large dot gain, which somewhat washes out the image.

Dye sublimation is better suited for outdoor use, as opposed to the other inks, Leto adds. With the ink ingrained into the fibers, the image is more durable against environmental elements. Solvent, UV-curable and aqueous inks are directly layered onto the fabric and can chip away when left outside. These inks tend to have a lower price point, though, and if you’re new to the printing industry, more options are available, which can widen your product line.

“With inks other than dye sublimation, you can print onto many other substrates, besides just fabric, and some may be interested in those inks because of the versatility,” Fisher explains. 

Direct-printable fabrics offer a fast turnaround time. UltraCanvas is used for this trade show display. Photo courtesy of Ultraflex Systems. UltraCanvas Backlit is used for this airport display. Photo courtesy of Ultraflex Systems.

DIRECT-PRINTABLE FABRICS & YOUR BUSINESS

Flags, banners, trade show exhibits and P.O.P. displays are all popular textile applications and well-suited for direct-printable fabrics. But besides fabric-specific applications, textiles often complement traditional signage pieces and add an eye-catching element, Bessette notes.  

“For example, if you have a storefront sign that promotes a sale and you add a direct-printed flag textile with a colorful graphic and the word ‘SALE,’ this will stand out more than the sign alone would have,” Bessette explains. 

Remember, signage isn’t the only suitable textile application. Even if you’re a sign shop, with direct-printable fabrics in your inventory, you can expand your product line by offering apparel. For apparel printing, Fisher recommends the dye sublimation process because the “hand” or feel of the fabric is not compromised. 

If you haven’t previously worked with textiles, Gallagher believes direct-printable fabric is an accessible entry point into the market, especially with today’s improved printer technologies, greater availability and affordable prices. 

“Printers being sold today, for the most part, are working well,” Gallagher says. “Customer are taking delivery and printing and making money within a few days. With the combination of reliable printers and high-quality, U.S.-made, proven fabrics, now is a good time to take the plunge and get into direct printing onto textiles.” 

However, Fisher maintains that those new to the textile market should initially stick with solvent, UV-curable or aqueous inks, instead of dye sublimation, for a less complicated process.

“Color correction is harder with dye sublimation because when a fabric first comes out of the printer, the color will look dull.” Fisher advises. “Color in the image won’t really pop until it is put through the heat press. That in itself is challenging.” 

When working with solvent, UV-curable or aqueous inks, once the textile is printed, the image is permanent, Fisher says, and no adjustments are required, which eases the learning curve. 

Breaking into the dye sublimation process can be difficult for beginners, Leto adds, as it’s a fairly mature market. Those who use dye sublimation have been doing so for many years, and competing against established shops as a start-up business is almost never easy. However, with solvent, UV-curable or aqueous inks, you have more printing options. 

Fabric is popular in the retail environment. These displays were printed on LexJet Water-Resistant Satin Cloth. Photo courtesy of Image Amazing, Hopewell Junction, N.Y.

GROWING IN THE FUTURE

Keep in mind, direct-printable fabric is still a relatively new application and has faced its share of problems that is typical of any emerging technology, Gallagher says. 

For instance, think of when cell phones resembled giant bricks that were attached to your poor, unsuspecting ears. Bulky and heavy with little battery power—early cell phones were a far cry from today’s sleek smart phones. But just as those clunky cell phones have been nearly forgotten, undependable direct-to-print textile technology is becoming a distant memory. 

“The printing technology is getting more and more reliable every year,” Gallagher asserts. “Printers are getting faster and cost less every year. Today, you can purchase 43-inch to 63-inch direct printers for under $50,000 and several under $40,000, and they work right out of the box.”

Besides improved printer technology, inks and coatings continue to advance, resulting in higher quality images, Fisher says, and Leto also notes that fabric durability is improving. Direct-to-print textile technology may be in its infant years, but as this application adheres to the demands of the industry, it will continue to grow in the future.