Neoflex DTG Printer Review

Neoflex 4880 DTG Printer

NEW $14,000
6.4

Print Quality

9.6/10

Production Speed

2.6/10

Reliability

5.2/10

Flexibility

7.5/10

RIP Software

8.5/10

Tech Support

6.2/10

Cost of Ownership

5.4/10

Pros

  • Large 17 x 42 print area
  • Load multiple garments at once
  • Great build quality
  • Great support system
  • Proven, award-winning print quality

Cons

  • Painfully SLOW print speeds!
  • Frequent parts replacement
  • Can't leave sitting for longer than a day
  • Print cost for larger images is huge!

The Neoflex DTG printer has been the leader in the industry for the last two years, and continues to be a proven solution for many small business owners.  The Neoflex DTG printer is built on the popular Epson 4880 Professional printer – it has been highly modified to act as a direct-to-garment printer, and great care has obviously been taken to ensure that the machine is built from the highest quality parts.  Although this is not the largest machine we have ever owned, it is one of the more well built models.  Since acquiring the Neoflex line of printers at our sister facility (www.fusionlogisticsgroup.com) over a year ago, we have been able to successfully turn out the highest quality product we have ever produced, while remaining more consistent and reliable during the production cycle.

EFFICIENCY

This printer offers a generous 17″ x 42″ printable area, which allows for “JUMBO” printing applications or for the inline printing of multiple items in a single pass.  The most common t-shirt setup is the “3-Up” configuration, which makes room for three average sized platens (11.25″ x 15″) to be loaded onto the print bed for maximum efficiency; each t-shirt in the lineup can have a different image printed on it, and of course the color of the garment doesn’t matter (in terms of functionality – there is certainly something to be said about the more logical approach of printing all “like colored” garments in the same run).  Rather than moving the substrate that is being printed, this model relies on a “flat bed / moving printer” design to accomplish its task – this design feature combined with the ability to line up multiple garments in a row for printing, allows the end user to load and unload garments as the printer is still in motion, thereby eliminating the “loading and unloading” phase from the production cycle.  Although someone still has to load and unload shirts, of course, the time required for this step does not cause any idle time on the machine.

Many people will argue that loading and unloading garments only takes a few seconds, which can sometimes be true; however, as someone who has employed many different people in the last several years, I can assure you that your low paid employees aren’t going to move with the same level of urgency that you might, and the loading and unloading phase will often be performed in a casual, slow demeanor.  This is made worse when dealing with specialty items such as hoodies or polo shirts, or when you consider how critical it can be to ensure that your substrate is smooth and flat (to avoid print head strikes that could potentially damage the machine) – some employees will work with the utmost caution and care when loading the shirts, taking time to carefully smooth them out before pressing print; while I certainly don’t mind the extra attentiveness from my staff, it is way better on the bottom line when the printer can be happily humming along while additional garments are being loaded and unloaded.

FLEXIBILITY

The flexibility of the Neoflex DTG printer is something that certainly sets it apart from the rest of the pack – as small business owners, who hasn’t considered adding additional decoration / print techniques to their arsenal?  Traditionally, the move to alternative substrates would require huge added investments, as most of the different ink chemistries can’t be used in the same machines – therefore, the only solutions were to either purchase a whole new printer to run an additional ink set, or to completely purge, flush and clean your system any time you wanted to swap ink sets to print on any alternate substrates.  Of course, this is neither ideal nor cost efficient.


The Neoflex employs a modular design structure that allows the individual printer units to be easily swapped out (I have long arms so I can move the printer by myself, but it’s easier with two people); it takes about two minutes to slide the print bed back slightly, unplug three cords and completely swap one printer unit for another.  This makes it much more practical to keep an additional printer unit on hand (an extra printer unit costs around $6,000, rather than buying a whole new printer for $20,000) in case one breaks down – in my experience, having redundant print capabilities is absolutely vital to ensuring the longevity of your DTG printing business.  As long as you have an additional printer unit on hand, there are many things you can do with it:

  • Store it in a closet somewhere in case you need to quickly get back to printing after a catastrophe.
  • Set it up as a “dual CMYK” garment printer to increase productivity on light garments, while reducing your overall manufacturing costs significantly.
  • Set it up as a Solvent printer to print on rigid substrates such as plastics, metals, wood, golf balls, CD’s / DVD’s and much more.
  • Set it up as an”edible ink” printer to print on cake topping sheets, cookies and other edible products.
All American offers a wide range of ink options and support consumables for each ink chemistry, allowing you to easily explore additional revenue streams without the need to purchase another $20,000 printer for one specific purpose.  Of course, if your primary unit were to ever fail, it would only take an hour or two to convert a “dual CMYK” garment printing unit into a “white + CMYK” printer, offering you peace of mind that you will always be able to complete a customer’s job on time.  It would be a little more difficult to convert a printing unit with a different ink set back to water based textile inks, but it is possible (the cost associated with purging out and thoroughly cleaning the entire system makes it impractical to do on a frequent basis).  When choosing which setup is right for your particular business model, proper planning and execution are critical – make sure you know where your business is headed, and be prepared to commit a full time effort to learning any new decoration technique.
In addition to being able to configure the Neoflex DTG printer in a variety of ways, you are also able to explore additional revenue opportunities by taking advantage of the generous print area (17″ x 42″ overall).  The flat bed design enables you to configure custom platens / holders for a variety of products, including pre-stretched art canvas, solvent-ready substrates such as pens / frisbees / USB drives / etc, and much much more.  Your creativity is truly the limiting factor with this machine, as it can sometimes take a little creative ingenuity to properly configure functional platen systems for various items.

DURABILITY

The major drive components of the Neoflex DTG printer are the massive lead screw which runs the entire length of the printer (this is what moves the printer), the primary motor that drives the lead screw, (4) individual motors that raise and lower the print bed and a host of sophisticated control hardware.  There is a common misconception in the industry that the Neoflex is simply a ‘copy’ of an earlier model of printer than All American paid a company to develop for them; the reality is that the Neoflex is a stronger, upgraded version of the same concept (a concept which was sound to begin with, which is why the company pursued it for so many years without changing directions rapidly or frequently like many other companies are tempted to do), which actually delivers on the performance and reliability promises typically expected of an industrial piece of shop equipment.

As soon as we add images to this particular review, we will include comparison shots of the actual drive mechanics of the two printers, illustrating some of the key differences.

COST EFFECTIVENESS

While the cost of the water based DTG inks used by most DTG machines seems to be priced way out of line, it is important to remember that there are still things we can do as business owners to make our businesses more efficient, and therefore make them more profitable.  Some things may involve changes to the order process, the use of an online ordering system to streamline the overall process, etc.  Other things can be done at the machine-level to maximize your efficiency, some of which we have already discussed.  For instance, the ability to load and unload the garments while the machine is continuously printing is a huge benefit in a production environment; this allows the Neoflex DTG printer to actually produce more ‘prints per hour’ than other 4880 based machines printing at the exact same resolution.  Additionally, the NeoRIP PRO (which actually processes the images and tells the machine exactly how to reproduce them on the garments) uses sophisticated image reproduction techniques which actually save ink and money, while simultaneously producing a richer print with greater depth and color.

One of the ways you can make the greatest impact on your bottom line is to properly take advantage of the modular design of the Neoflex system; if your goal is to print on t-shirts, then t-shirt printing should be your first and only focus until you have the process dialed in to perfection.  By investing in one additional printer unit (which can be quickly and easily swapped out on the machine at any time) and configuring it for “dual CMYK” printing (using the same water based garment inks you are using to print on dark garments), you can effectively move all of your dark garment printing to one machine and all of your light garment printing to another.  The cost effective advantages that this provides are twofold:

  • Any DTG printer, desktop inkjet printer or general purpose printer will perform automated maintenance on the print head at scheduled intervals, often related to the number of prints that have been completed since the last cleaning or purge cycle.  Inkjet printers are required to keep the print heads clean and primed, and to prevent them from drying out; this is achieved by firing a small amount of ink from each channel at predetermined intervals during the printing process, regardless of whether the channels are currently being used to print.  How does this affect a DTG printing business, you might wonder?  As you are printing “light garments” (those which do not require a white ink under base), the printer will continue with its automatic cleaning cycles, forcing a small amount of white ink down the drain after every number of print cycles – since many DTG printers find themselves decorating about 70% light garments compared to only 30% dark garments, it would be very easy to print one or two thousand white t-shirts in a given month and find your cartridges of white ink half empty even though you haven’t printed a drop on any dark garments.  Many DTG printers sit around at the end of the month wondering where the hell all of their white ink went, and this is just one source of waste in the overall process; by printing all of your light garments on a separate “dual CMYK” printer unit, you could print 10,000 light garments and not waste a drop of white ink.
  • By printing all of your light garments on a “dual CMYK” printer unit, it is possible to achieve the same amount of ink saturation at half the resolution, since the machine would be using (8) channels of CMYK instead of the normal (4) channels that would be used (since the other 4 would have been filled with white ink).  By doubling the ink output in a single pass (thereby allowing a lower print resolution to be used) you are able to print at a much faster rate, significantly increasing your production numbers on light garments – since light garments are the ‘bread and butter’ orders for many small and medium businesses, this has a huge impact on the overall bottom line.
As you can see, with the proper business planning and configuration, the Neoflex DTG printer offers a wide range of options for startup companies and existing businesses looking to expand their market – these options allow for greater productivity, increased profitability and a more attractive ROI for business owners.  I would probably go so far as to say that the Neoflex is one of the top DTG machines in its class in terms of cost effective operation, when done properly.  The more ‘generalized’ you want to be with your business, the more your cost effectiveness will suffer; if your goal is to print t-shirts, be sure you make t-shirt printing as profitable as possible before moving on to other markets.  That is just our advice over here at DTG Print Solutions, anyways.

SUPERIOR COLOR MANAGEMENT / INDUSTRY LEADING RIP SOFTWARE

Any company can re-package an existing RIP and say that it is compatible with their particular DTG printer.  However, when a company decides to take the time to tailor the color profiles and image handling properties to achieve the optimal print quality for that particular setup, that is when they set themselves apart from the rest.  The team at All American has put in a great deal of work in their endless pursuit of perfect print quality – with custom color profiles, custom ink curves, precise dot control optimized for each substrate / print resolution, they have continued to raise the bar for everyone around them.  The Kothari-based RIP software is already the most powerful RIP in the industry, but coupled with more specialized color profiles it is able to produce some of the best prints we have seen from any DTG printer.

Since we purchased our printers over a year ago, I have watched as the guys over in Philly have created new custom printing environments, while also dialing in each color profile for “high resolution” printing, “high production” printing and much more; with so many ink sets to deal with, I am honestly amazed that they are able to get anything done over there…. However, they somehow manage to do it and we as end users benefit from their ongoing efforts to be the best.

Besides the adjustments and improvements that All American has made “in house”, the fundamentals of the RIP itself are stunningly powerful.  The ability for the RIP software to so cleanly and accurately recreate graphics from the screen onto cotton t-shirts is unlike anything I have seen in the past – since I first noticed the incredible disparity between this brand of RIP and the next leading competitor about a year ago (which, btw, opened an entire hornet’s nest in the process), there have been many tweaks and improvements from the competition, slowly shrinking the initial quality gap (strictly in terms of smooth, crisp image detail and accurate reproduction – color profiling is the other side of the coin).  To this day however, I have not seen an image reproduced as cleanly on any other printer using any other RIP.  Some people will argue that increased quality above a certain threshold is unnecessary – however in the last six years I have run into the perceived “limits” of DTG quality on many, many occasions, and always something or someone eventually comes along and shatters those barriers.  Better inks, better pre-treatment, better RIP software, better hardware, etc.  I think we should never stop pushing for faster printers, lower consumables costs and of course, ever increasing quality.  Some people say we don’t need to reproduce the Mona Lisa on a t-shirt – I say “why not?”

GENERAL SUMMARY

….. coming soon.

142 thoughts on “Neoflex DTG Printer Review

  1. My partner and I absolutely love your blog and find a lot of your post’s to be just what I’m looking
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  2. Print Quality

    10.00

    Production Speed

    2.00

    Reliability

    6.50

    Flexibility

    10.00

    RIP Software

    9.00

    Tech Support

    8.50

    Cost of Ownership

    6.50

    The Neoflex DTG printer was the best choice we made, when compared to so many other failed DTG printers…. They really went to great lengths to build a higher quality machine (larger motors, lead screws, etc) and the tech support team was some of the best in the industry. However, when you have such a large user base, there is no way the tech support team can provide a reliable response / solution time in an industry where these things are absolutely the most critical. The best decision All American ever made was choosing to offer the Kothari RIP with their equipment, as the difference in the output quality between the “original” NeoRIP vs the Kothari-based NeoRIP PRO was QUITE LITERALLY night and day. Beyond this, they took the time to make some really nice color profiles to accommodate both white and black t-shirts… They even made a profile for red shirts, at one point. However, there was a relatively broad range of garment colors which still needed more adjustments to create comparable results, and this was often bypassed with a dismissive “we’ve working on it”…. We owned our Neoflex printers for nearly three years, and the only “new” color profile we received was the one for red garments. The entire tech support team at AA was fantastic, but it was a bit of a problem when their best guys kept getting moved into sales positions – of course this was better for them, individually, we felt it ultimately detracted from the overall quality of the tech support services.

    The Neoflex printers helped moved the industry forward in a big way, by packaging the best possible RIP software with a solid hardware platform – unfortunately, it came too early as the basic ink chemistry and fundamental Epson platforms were still not quite up to par. Some people have had great success with these printers, as we did for quite some time, but ultimately it was frustrating being in a position where 2 out of 3 of our Neoflex printers were constantly down or in need of maintenance…. The company, however, has an inherent understanding of general quality and we do expect these basic issues will be addressed in the future, as the industry advances. This is of little consolation to those who invested so much in these early years, but with everything else we have seen in the last 10 years of DTG development, it seems we are definitely on the right track!

  3. Print Quality

    10.00

    Production Speed

    3.00

    Reliability

    6.50

    Flexibility

    10.00

    RIP Software

    10.00

    Tech Support

    7.00

    Cost of Ownership

    7.00

    We used the Neoflex for about a year and it produced incredible quality prints. The problem we had was mostly with non-black and white shirts; the color profiles between the different garments was very noticeable and created a number of problems for us. All American always said that the new color profiles were “coming soon”, but we didn’t really get any updates during our year of ownership. As with all DTG printers, you can’t let the machine sit for longer than a day without having serious issues with ink settling and clogging – it is very easy to ruin a print head and the replacement cost is crazy. Tech support was very good, but we didn’t always get an immediate response to our questions – sometimes we would reach different tech people and they would ask us to go over all the same things we covered with previous techs. Overall, a good company to work with but remember you aren’t going to have anyone holding your hand during this process…. Be prepared to become an Epson tech if you want to keep it running, all the time.

  4. Print Quality

    9.00

    Production Speed

    1.00

    Reliability

    5.00

    Flexibility

    5.00

    RIP Software

    9.00

    Tech Support

    5.00

    Cost of Ownership

    5.00

    Having owned the NeoFlex for several years I was always impressed with the print quality. However many other things have been lacking and not addressed as the machine has aged over the years. Once AA stopped using DreamJet Korea for the engineering, parts and R&D things have not been nearly as stable. This comes from first hand experience using the v1 DreamJet built NeoFlex and the v2 AA internally built NeoFlex. The current NeoFlex is a dinosaur in today’s competitive DTG market and AA is now working on bringing a new 3880 based flatbed printer and an R3000 desktop printer to market.

    PROS:
    *Great Print Quality (RIP)
    *Large Print Area
    *Multiple Ink Options (Textile, Solvent & Edible)
    *Ink Prices (textile)
    *Strong Tech Support Team

    CONS:
    *Insanely Slow Print Times (for today’s standards)
    *Large Foot Print
    *Excessive Delivery Wait Time (Expect 3-6 months for delivery)
    *Printer was devalued 40% by AA leaving many upside down on their investment
    *No Hardware/Software Updates in 36+ months
    *Sagging Bed
    *Warped Platens
    *Low Resale Value
    *Replacement Parts becoming harder to get
    *Dependent on Epson’s technology and supply chain

  5. Print Quality

    9.90

    Production Speed

    2.40

    Reliability

    6.20

    Flexibility

    4.90

    RIP Software

    8.60

    Tech Support

    7.00

    Cost of Ownership

    7.00

    First off, My review was done mobile so sorry for the random decimal point ratings, but they are accurate for the most part.
    I have owned a Neoflex for 3 years now and have had my ups and downs with it. That being said this was my first DTG printer so there was quite a learning curve which made for a rocky first year. Reviewing this printer to me seems a bit at this point for the fact that All American likely will not be selling the original Neoflex 4880 for much longer since they have released a new 3880 and a 3000 Neoflex. Print quality is awesome with this printer – likely the best you can get in the DTG world. The rip program is very easy to use and for most prints it is plug and play with the profiles that AA has created. It is still lacking in a few areas, but I have been told that compared to most rips this is too notch, so I don’t have many complaints. The three up platen loading is also pretty great for production. Some may argue that having a single platen printer with an extra platen to load and insert each time is just as quick, which may be true, I have no experience with that. Inam now comfortable taking the printer apart because the reliability isn’t always there, though, more often than not I am up and running which is why I rated it a 6 (over half). Trouble shooting isn’t always an easy task with so many variables that can play into the cause of a problem that may arise. I rated the printer fairly low on flexibility because the platens it comes with are pretty much useless for anything besides standard front and back Tshirt printing. If you want to print hoodies, pockets, sleeves, youth, high upper back prints, etc, expect to make your own solution/platens for it. Production speed is very slow in high resolution mode and using the production mode that prints a bit faster (but still not fast enough on darks) is not always a solution because it does not lay down a solid enough white for a good print. Parts for this printer are becoming more scarce than ever which makes the price higher. That being said I still gave a good rating for cost of ownership because the consumable ink is the lowest price on the DTG market. Overall, aside from the slow print speeds, I am happy with my Neoflex most of the time, until I am spending my day trying to solve an issue again with jobs backed up. If today was one of those days I may not be saying that because it can be extremely frustrating!

  6. Print Quality

    10.00

    Production Speed

    6.00

    Reliability

    3.00

    Flexibility

    8.00

    RIP Software

    8.00

    Tech Support

    8.00

    Cost of Ownership

    4.00

    I would not only just suggest, but I would say it is mandatory to get this machine if and only if you have another printing technique already going for you. Fortunately, we have screen printing and vinyl printing departments and thanks to those for keeping me afloat during the times this machine was down. In addition, they allowed me to take hits (in terms of $$$) when I needed to buy replacement parts or refund customers for not meeting their deadlines.

    The team at All American was great and especially LEO who is a rockstar customer service technician. Unfortunately, my problems persisted despite being on the phone with them consistently.

    I believe the cause of all my errors was the humidity I had in the room. It was never consistent and I had a tough time keeping it above 45% humidity. I am not positive on this though, because I have talked to other owners that say they keep humidity in the 30% range and run this machine day in and day out without any problems.

    In a nutshell, I would say this machine is for an established shop and DEFINITELY not for somebody that is just entering the industry.

  7. Print Quality

    8.70

    Production Speed

    1.50

    Reliability

    2.30

    Flexibility

    6.10

    RIP Software

    6.00

    Tech Support

    1.00

    Cost of Ownership

    2.00

    We’ve owned a Brother GT-541 almost since the day it came out. We love it. The drawbacks were simple – no white ink, and the cost of ink and replacement parts single sourced through Brother.

    After going to ISS, and doing a detailed analysis, We purchased a gently used Neoflex in June 2013. I had spoken to people at AA, and they had an aftermarket warranty package for purchase that made it a reasonable choice.

    Justin and his team picked it up and delivered/installed it at our location. This is when we found out that AA no longer offered the aftermarket warranty The printer worked well with CMYK designs, but we had problems with white – clogged lines, dampers, etc. These were replaced, but because of the time required to do so, we didn’t get the PRETREATMENT process down well while they were in town to train us. AA doesn’t want to support us in any way simply because we bought a used machine.

    Very shortly after we got our Neo, my business partner (and husband) became disabled enough that he couldn’t run the machine, and had little interest in learning a process that only worked part of the time – and resulted in an inferior product the rest of the time.

    And the neoflex has been sitting with cleaning solution in the lines since August 2013, not ONCE printing a shirt for profit.

    Roll forward to May 2015 – our Brother is getting very old, and we need to look at a new printer. Do we convert the Neo to dual CMYK and run with it? I think we will do that. We’ll post another review after that time. We have an Epson repair facility here in town – I can get new heads, lines, and dampers pretty easily. Wish us luck.

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