clothing & merchandise print processes

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Here at Firepower Design & Print, when it comes to printing clothing such as t-shirts and hoodies, workwear, sports, gym, and team wear etc., we use any one of 4 different printing methods. Your artwork and specific requirements will determine the most suitable method required to give you the best possible results.

The following are the 4 different methods we utilise :

DTG

dtg - direct to garment

Due to the ultimate combination of full colour detail, versatility and durability, this print process is the most popular and standard print method used to produce High Street quality garments. Direct To Garment, or DTG as it is more commonly known, is the perfect application for creating dramatic, brilliant, colour rich prints from basic artwork, right up to full colour complex designs on white, light and dark coloured fabrics.

As the name Direct To Garment implies, the artwork forms part of the garment due to the fact that it's sprayed directly on to the fabric using non toxic, water-based inks that are soft to the touch, and also stretch along with the fabric.

Direct To Garment printing is a 2 stage process using state of the art technology, equipment and inks. Firstly, a fixing agent known as pre-treatment fluid is applied directly to the surface of the garment, which is then subjected to heat and high pressure in order to cure it prior to printing. Secondly, during the printing process itself, depending on how dark the fabric or substrate colour is, a varying amount of white ink is laid down on top of the fabric. The base layer of white ink is what gives the colours a much more vivid and punchier look on the darker fabrics, hence why white ink isn't needed if the fabric is already white. It's the pre-treatment stage that causes a chemical reaction with the white ink in order for it to bond with the fabric weave, which in turn is what gives the print it's excellent durability. Then, a layer of CMYK (Cyan, Magenta, Yellow, Black) inks are applied over the top of the white and then cured under heat, which then completes the printing process.

The stage 1 pre-treatment part of the printing process explains why, upon receipt of your newly printed garment, you may well notice a starch-like feel to the fabric surface and sometimes a slight smell, or even a slight brown discolouration on the lighter garments.

This is perfectly normal and nothing to worry about, and is common across the whole Direct To Garment (DTG) printing industry. It's not permanent and should all disappear after the first wash. It is recommended to wash DTG printed garments inside out at 30ºC, allowing them to dry naturally, not tumble dried, and by not ironing the print itself. Washed accordingly, the print will last as long as the garment.

Direct To Garment (DTG) printing is only suited for fabrics that have an absolute minimum 80% regular or organic cotton content.

dtf - direct to film

Direct To Film printing, also known as DTF, is a relatively new technolology that continues to grow in popularity.
The process utilises a Direct To Garment (DTG) printer using the same water-based inks, to print designs on to a special coated film known as PET, or Polyethylene Terephthalate. The printed film is then covered in a hot-melt thermo-adhesive powder, which only applies itself to the wet ink of the design. The DTF Film is then subjected to heat which transforms the powder in to an adhesive. It's this adhesive that will bond the coloured pigments in the print to the fibres in the fabric, or to the surface of other compatible substrates. The printed film, or transfer as it's commonly known, is then applied to the garment, or other substrate, all done using a combination of specific heat, pressure and time settings.

Direct To Film (DTF) is suitable for white, light and dark coloured fabrics. On white fabric or substrates, only CMYK (Cyan, Magenta, Yellow & Black) ink is used. On light and dark coloured fabric or substrates, the CMYK is printed down first and then, depending on how dark the fabric or substrate colour is, a varying amount of white ink is then laid down over the top. The layer of white ink is what gives the colours a much more vivid and punchier look on the darker fabrics and substrates, hence why white ink isn't needed if the fabric or substrate is already white.

The Direct To Film (DTF) process has it's own advantages over other traditional printing methods. The design artwork itself has a crisp and well defined edge, which is very difficult to achieve with processes such as screen printing or, to a lesser degree, Direct To Garment (DTG).

In comparison to Direct To Garment (DTG), transfers created using the Direct To Film (DTF) method can be applied to a much wider variety of fabrics and substrates, such as polyester, leather, silk, nylon or synthetic fibers like rayon or terrycot, and especially fabrics with an open weave.

DTF

inks used

Our Direct To Garment (DTG) and Direct To Film (DTF) printing uses water based inks that are :

100% Non-toxic
100% Organic
Vegan and Eco-friendly
Free from animal by-products and testing
A waterless process so no water is wasted or polluted by inks
ECO-Passport by OEKO-TEX®
OEKO-TEX® 100
OEKO-TEX® Class 1
Global Organic Textile Standard (GOTS)
REACH Compliant
Chemical free from heavy metals, formaldehydes, Alkylphenol Ethoxylates(APE) and organic tin compounds
100% safe for children and babies

Water-based ink does not include plastic, which makes it a more eco-friendly option in comparison to plastisols. Water-based ink can produce some of the softest and lightest impressions, in some cases (depending upon the type of print process used) with virtually no difference in hand feel between the imprinted and non-imprinted sections of the finished piece.

htv / htf - heat transfer vinyl & flock

HTV stands for Heat Transfer Vinyl, and is also known as Heat Press Vinyl (HPV) or Vinyl Flex, which is usually either a polyurethane (PU) or poly vinyl chloride (PVC) material. These come in standard, block colours, along with speciality patterns (eg. Carbon Fibre / Camo / Glitter), and is applied in accordance with the manufacturer’s recommended temperature, pressure and time settings.

Heat Transfer Flock (HTF), is essentially the same as Heat Transfer Vinyl (HTV) other than it has a 3D type, velvet-like texture and feel to it, which makes it stand slightly proud of the fabric it's being applied to, and as such is a great substitute for embroidery.

Heat Transfer Vinyl (HTV) & Heat Transfer Flock (HTF) is mainly used for applying text or simple, uncomplicated designs onto garments such as t-shirts, hoodies, sweatpants, gym & sportswear etc. It's suitable for all types of white, light and dark coloured fabrics.

Depending upon the types of Heat Transfer Vinyl (HTV) & Heat Transfer Flock (HTF) being applied, it's usually possible to create a number of different designs using up to a maximum of 3 colours, and is achieved by using what's known as a multi-layering technique.

We will select the right type of Heat Transfer Vinyl (HTV) or Heat Transfer Flock (HTF) for your specific job requirements and your chosen item fabric.

The types of fabrics that we can apply HTV & HTF to, are :

Cotton, this includes performance and tri-blend fabrics
Polyester
Poly-cotton and Spandex / Lycra mixed fabrics
Coated and Uncoated Nylon

*Heat Transfer Vinyl is available in up to 40 colours creating a vibrant, matt or satin finish, and up to 20 colours for Heat Transfer Flock. Our Heat Transfer Flock (HTF) is available in 2 types, Premium & Regular. Both Heat Transfer Vinyl & Flock are extremely durable and, subject to washing in accordance with the supplied guidelines, should last for the industry standard rating of a minimum of 50 washes.

Our Heat Transfer Vinyl & Flock is :

Vegan & Free from animal by-products and testing*
Eco-friendly
OEKO-TEX® Class 1 Certification
REACH Compliant
Chemical free from heavy metals, formaldehydes, Alkylphenol Ethoxylates(APE) and organic tin compounds
100% safe for children and babies

*With the exception of Premium Flock

HTV

dye sublimation

Dye sublimation printing is a digital printing method producing brilliant full-color, crisp, high-quality, durable images where specially formulated ink (in craft circles, often referred to as infusible ink) is heated up and pressed onto a substrate by undergoing sublimation. Sublimation ink is unique due to it's ability to convert from a solid to a gas without passing through the liquid state in between.

A sublimation printer and specially coated paper are used to create the transfers that are then applied to the fabric or substrate under specific heat, pressure and time settings.

Substrates suitable for sublimation, with the exception of polyester fabric, have a special polyester coating that allows the penetration of the gaseous sublimation ink to embed itself within the product. The way this process works, is that polyester fabric and substrates with the special polyester coating have pores, a lot like human skin. When heat and pressure is applied, the pores open up and allow the gaseous sublimation ink to penetrate under the surface, rather than sitting on top. The applied pressure helps the ink return to a solid state and then during the cooling process, the pores close and trap the ink inside the coating or fabric. Once embedded, the result is permanent and the colours stay vibrant, won't fade, peel or crack, even after multiple washes.

Our mugs, for example, are microwave and dishwasher safe and guaranteed for a minimum of 2000 wash cycles.

*Sublimation only works on light coloured fabrics and substrates, with the very best results being achieved when applied to white backgrounds.

Compatible Materials & Substrates :

Polyester & Poly-cotton Mix Fabrics
Polyester Type Surfaces such as mouse mats
Polyester Coated Ceramics, Aluminium, Metal, Plastic & Wood
PVC

We use water-based sublimation ink using non-pigment based colorants and materials therefore contain no known heavy metals including Cadmium (Cd), Chromium (Cr), Lead (Pb), Mercury (Mg), Arsenic (As), Antimony (Sb), Barium (Ba), Cobalt (Co), Nickel (Ni), Selenium (Se) and Zinc (Zn) and are;

100% Non-toxic
Vegan and Eco-friendly
Free from animal by-products and testing
A waterless process so no water is wasted or polluted by inks
OEKO-TEX® Certified
REACH Compliant
Chemical free from heavy metals, formaldehydes, Alkylphenol Ethoxylates(APE) and organic tin compounds
100% safe for children and babies

Water-based ink does not include plastic, which makes it a more eco-friendly option relative to plastisols. Water-based ink can produce some of the softest and lightest impressions in some cases (depending upon the type of print process used) with virtually no difference in handfeel between the imprinted and non-imprinted sections of the finished piece.

Dye Sub