Tag Archives: printer

How to Print on Wood Using DTG (Direct to Garment) Printing

NOTE: This article comes from KatanaDTG.

Printing on wood is fun and easy with most direct to garment printers.  As long as you have the ability to adequately adjust the z-axis height (the relative distance between the print head and the substrate), the process is relatively simple!


  • Blank wood panels (the ones we used are available from Hobby Lobby and other craft stores)
  • Masking tape or painters tape
  • White gesso or water based primer
  • Paint brush
  • Acrylic finishing spray to protect the printed image

STEP ONE: Wipe down each piece of wood to remove residual sawdust and other debris.

STEP TWO: Mask the outside edges of the wood with tape.

Using a low-tack masking tape, tear off small pieces and work your way around the border of the wood.  This allows you to preserve the outer bark layer, which enhances the final appearance of the printed wood.  If you are using pieces of wood without bark, you can simply tape around the outside edges to prevent runoff from the primer layer or overspray from the printing process.

STEP THREE: Coat the wood in some sort of water based primer or white gesso.

The gesso (or primer) allows the inks to adhere properly to the wood, creating a beautiful print.  You can use any sort of white water based primer, white gesso (a common painting product artists use to coat their canvas prior to painting), or even a clear gesso if you want more of the wood grain to show through.  For this example, we used a Bob Ross brand white gesso, available from Hobby Lobby and other craft supply stores.  Allow the primer coat to fully dry, prior to moving on to the next step.

STEP FOUR: Measure the wood (we’re gonna gloss right over the myriad of joke opportunities) and set the general size of the artwork in the RIP.

Measure the width and height of each piece of wood, prior to attempting to print.  Set the width / height to ensure the printed image will cover the entire piece of wood.  This step can take some practice, as you want to ensure all critical parts of the image are printed within the boundaries of the odd-shaped wood – make sure you select each piece based on its general compatibility with the desired artwork.

STEP FIVE: Print a test image for alignment.

Tape a piece of paper (or paper towel, in our case) to the platen, lower the ink volume significantly to reduce potential bleeding, then print a test print directly on the paper.  Once the image is printed, tape the wood in the desired location, directly on top of the test print – make sure you adjust the z-axis at this point, to accommodate the thickness of the wood (once again, glossing right past that).

STEP SIX: Print your image!

SOME NOTES FOR ADJUSTING YOUR PRINT SETTINGS: We used Kothari RIP on a Katana PRO printer, so we made a series of specific adjustments to get the best results on each piece of wood:

  • Printed in high resolution, 1440 x 1440 mode

  • Changed to uni-directional printing rather than bi-directional, allowing for more flexibility on the print head height

  • Lowered the color volume to 35% to prevent bleeding

  • Added a 300 ms delay between each scan line pass, allowing more time for ink to dry

Once your image has been printed, you can remove the masking tape from around the edges of the wood – your incredible wood print is nearly done, at this point!

FINAL STEP: Apply a clear acrylic top coat to protect the printed image.

You can use almost any type of clear acrylic spray coat for this step – the point is to seal in the image, since we don’t actually heat set the ink at any point.  You can purchase various types of sealants at any art or craft store, or swing by your local hardware store and purchase a can of clear acrylic spray.


How to Properly Prime a Bulk CIS Ink System

A few years ago, we never would have recommended a bulk CIS system for ink delivery into any DTG printer.  However, with recent advances in ink chemistry stability, many of our users have been switching to bulk systems with great success!  It is our goal to provide current and useful information to our entire user base, to ensure everyone has the best tools available for their long term success.  Along those lines, we have done extensive testing with a variety of bulk CIS systems and have determined that our preference is for systems which have an air chamber in the actual bulk ink reservoir.  Our testing indicates superior reliability with such systems, although we have determined there is certainly a right and wrong way to fill these units!

NOTE: This article comes from KatanaDTG user Knowledge Base.

This tutorial is meant as a starter guide for properly loading a bulk CIS system for direct to garment printing – please note that these systems are designed to maintain a balance of ink and air, so properly managing your rubber plug arrangement is crucial!


Almost all bulk CIS ink systems are manufactured overseas, and while most are relatively reliable there will be an occasional manufacturing or assembly error which can result in serious problems for DTG end users.  Before attempting to load ink into your new bulk system, take a good look from every angle to determine if there are any potential issues with the system, itself.  In particular, you want to ensure that the ink line leading out of the reservoirs are routed smoothly along the bottom side of the assembly.  This is a major pain point for DTG users – a kinked line can lead to back pressure in the system, which will prevent ink from flowing along a particular path.


NOTE: A kinked line can be deadly for DTG users.  The line starting from the Yellow reservoir can be a particularly annoying pain point, as this can sometimes be pinched if it is installed at an aggressive angle.  Below is an example of smooth ink line routing in a bulk CIS system!


The rubber plugs for any CIS system are an important, yet often undervalued asset.  These plugs allow you to properly balance the volume / flow of ink and air in the reservoirs.  The plugs should be fully closed when the system is not in use, but when performing any functions on the printer which require the positive flow of ink, the Breather Plugs MUST be open!  If these plugs are closed during printing, priming or cleaning, a back pressure vacuum will be created as the system attempts to pull a closed ink line.

The Fill Plugs should be closed at all times, except when refilling a reservoir.  Before opening any Breather Plug, ensure you have fully closed the corresponding Breather Plug for the duration of the process!


Open the Fill Plug for the reservoir you wish to refill – also ensure that the corresponding Breather Plug is closed.  Using a small funnel or syringe, fill each reservoir to an appropriate level.  Once completed, close the Fill Plug, ensuring a proper seal.

NOTE: If done correctly, ink should remain in the primary chamber, while air remains in the rear chamber.  This balance is important for proper ink flow!

Below is what the system should look like, once you fill each ink chamber – keep in mind the MK is left empty, or loaded with a light cleaning solution.  The PK / MK chambers are both routed to the same channel in the print head, and since we don’t switch between the two lines during normal DTG operation, the last chamber is left unused.

NOTE: Remember, the air chambers in the back of the reservoirs should remain empty after filling the system!  Make sure the Breather Plugs remain in place before opening any corresponding Fill Plug.

As you fill each ink reservoir, you will hopefully notice ink flowing naturally down the lines until they reach a balance – while they won’t flow completely to the ink cartridges, they should flow easily with the help of gravity.

NOTE: On the p600 print engine, ink is internally pressurized once it is pulled from the cartridge into the printer system, itself.  This helps considerably with smooth operation and ink flow!



  • Make sure you have proper syringes which fit snugly into the bottom of the cartridge.
  • Make sure you have properly filled your bulk CIS system, so there is ink to draw into the carts.
  • If ink does not begin to flow immediately, try shifting your syringe side-to-side, slightly, to ensure you have fully opened the rubber seal – you may also want to ensure you have fully inserted the syringe into the cartridge.


  • Try to keep the opening of the cartridge facing upward most of the time – the point where the syringe enters the cartridge is the last place you want ink to flow.
  • Keep your fingers away from the chip on the side of the cartridge, as it can affect the functionality if you get grease or residue from your skin on it.
  • Try to ensure the chip on the side of the cartridge is always facing uphill from any potential ink drips or spills.
  • While there should be some expected back-pressure, if you feel an extreme amount of resistance you should stop and inspect your system.  Look for “pain points” where the ink lines may be kinked, or otherwise obstructed.  If everything looks clear, try shifting your syringe slightly until you see / hear / feel the ink begin to move.


Once your CIS system is fully primed, you need to move the ink from the cartridges to the print head.  To do this, use the Epson Adjustment Program to run an initial Ink Fill routine, which will subsequently prime the entire print engine!

NOTE: You can only run an Ink Fill routine if the Epson print engine thinks you have brand new cartridges installed.  Use a manual chip resetter to fool the system into recognizing brand new cartridges – it can sometimes take several attempts to fully reset some chips.

KatanaDTG r3000 / p600 DTG Printer – User Reviews

The KatanaDTG printers are well built, with plenty of great features that make printing and maintenance easier.  The modular print system makes it easy to swap modules in seconds, and the threadable platens load just like a standard screen printing press.  Kothari RIP is included as the standard and ONLY option, because nothing else compares to the print quality available from this particular software.  Complete with easy-access maintenance panels and an electronic z-axis control, the Katana line of DTG printers is a competitive option for an incredibly low price.

The newest p600 series includes the ability to run a one-touch Purge, as well as one-touch access for the capping station and wiper blade.

Belquette Mod1 DTG Printer – User Reviews

The Mod1 is Belquette’s second foray into the DTG market, following the PRO series Flexi-Jet.  Based on a modified Epson r1800/r1900 print engine, this A3 style printer is quick, boasting a range of high tech features and an innovative appearance and construction.  The ability to independently control either of the z-axis motors for maximum control is a huge plus, but some might find the auto laser level to be somewhat restrictive.

The Mod1 boasts a modular design for quick and easy print module swaps, as well as a bagged ink system for bulk convenience.

Print Size: 13″ x 19″(x 6″ Z-axis height)

Spectra r3000 / p600 DTG Printer – User Reviews

One of the first serious competitors in sub-$10k DTG printer market, Spectra has justified the market and made it far more viable.  The flagship product for Spectra DTG is the r3000 and p600 versions of their A3 DTG printer.

Spectra espouses an affordable, minimalist approach to DTG, foregoing many of the traditional “bells & whistles” of other printer in exchange for an incredible affordable cost.  A modular build allows for easy swaps and upgrades, so it is easy to experiment with additional configurations (white + CMYK, dual-CMYK, etc).

Rate your DTG printer! The New Consumer Reports for the DTG Industry…

Have  you been involved in DTG printing for some length of time, and want to provide your feedback for a specific DTG printer model?  We have now introduced the new Product Reviews function for DTG Print Solutions, allowing for full length, in-depth equipment reviews as well as associated follow-up rankings by the general community!

Once a review has been placed, any logged-in user can add a Comment (complete with their unique rankings for each of the provided categories) and the total product review will reflect the subsequent ratings calculation.  By adding your rating, you are contributing to a global community of DTG users with the intention of providing valuable insight and information for any potential buyers.


Whether your particular experience was good or bad, your feedback can help other users make a more informed decision in this process.  Be honest about your experiences and include any comments which could provide potentially useful information for someone contemplating the purchase of a particular piece of equipment.

Don’t see your particular printer listed?  Consider being the first to review your DTG printer (or equipment accessory) by contacting us at info@dtgprintsolutions.com – we would love to receive additional feedback from the general community, regarding DTG printers we have not been able to personally review!



Buy and Sell DTG Printers and Accessories in the NEW Community Marketplace!

We are working hard to improve DTG Print Solutions, with the intentions of providing the best tips, tricks and resources for the DTG printing industry.  With this in mind, we have created an area on our website called the Community Marketplace, which we hope to build into the premier marketplace for used (and possibly new) DTG printers, pretreat machines, supplies and lots more!

buy-or-sellHOW DOES IT WORK?

Anyone with a used DTG printer, accessory or assorted supplies can post ads in the Community Marketplace.  The system works similar to the popular Craigslist platform in terms of self-moderation and management; you create your own ads, upload photos and a detailed description of what you are selling, then post the ad – buyers contact you directly (you can mask your e-mail address when posting) and all transactions are handled privately.


Guidelines for Posting Ads:

  1. Neoflex Printer in ActionBe Honest and Transparent – Don’t Skimp on the Descriptions: Make sure you describe what your are selling honestly and accurately.  Describe the condition of the equipment, and don’t leave out any flaws or broken parts.  Buyers of used DTG printers often understand what they are looking for, and any information they can get about what might need replacing will not only allow them to make an informed buying decision that is compatible with their specific business model, but also help ensure a more successful and enjoyable experience for both parties.  Any ads with false or misleading information will be removed.
  2. Be Tidy: Please be sure you delete your ad once your equipment is sold.  This will prevent a bunch of follow up leads trying to contact you after your printer has been sold, and it will allow potential buyers to focus on the most current and relevant listings.
  3. Use High Quality Photos: Small, grainy photos don’t show anything and do little to help enable a more informed decision for the buyer.  Make sure all photos are of decent size and quality, and try to highlight the important aspects of whatever you are selling.  Photos sell products, so please take this step seriously.
  4. Offer Your Buyers a Great Deal: We all know the used  DTG printer market is tough – these products tend to lose value quickly in this industry and it breaks our heart to take a major loss after (often) such a short period of time.  However, make sure you are pricing your equipment realistically, understanding that the main reason most people buy used is to save money.  Offer your potential buyers a great bargain and your listing won’t last long – the better the bargain, the faster your stuff will sell!  Also don’t forget to describe any additional supplies, equipment or replacement parts you are including in your listing (if any).


For buyers, this will create a concentrated supply of options to make the buying process easier, while hopefully providing for the best possible deals and the fastest way to compare printers and accessories!  Keep the following points in mind, when considering used equipment:

  1. DO YOUR HOMEWORK!  DTG printing is not easy, whether you buy new or used.  Make sure you know what you’re getting yourself into and find out everything you can about your potential purchase.  Ask about any parts that might need replacing and ask why the user is selling their equipment (don’t necessarily take it at face value when they say “they machine is great, I just don’t have the clients to support it”).  Go online and research any brand or model prior to making a decision, and whenever possible, try to see the machine printing in person, before you make any commitments!  This is a major decision, so take your time and be smart about the process.  Caveat Emptor (“buyer beware”).
  2. Try to See the Equipment in Action, Prior to Purchasing: Although this was mentioned above, it merits repeating.  Nothing will tell you more than actually watching a machine print, while evaluating the actual print speeds, ink costs, output quality, etc (preferably with artwork of your own choosing).  If there are any major issues, or if it takes a long time to finally get a decent print, you can understand these before you actually take the printer home.  Many people tend to remove the ink from their machines, once they decide they don’t want to do DTG printing anymore – it isn’t always feasible to ask them to re-ink their machine, but someone who wants to make the sale and who is supremely confident with the condition of the printer should be able to accommodate such a request…  After all, this is usually not a small purchase.
  3. Any Deals Made are Strictly Between the Buyer and the Seller: DTG Print Solutions is not involved in any way with any specific transaction, and we do not warrant or guarantee anything that is bought or sold through the Community Marketplace!  Just like Craigslist, we provide an open marketplace for users to buy and sell, and it is up to you to do so responsibly.  Unlike Craigslist, we provide a highly targeted stream of traffic and a very refined type of products and equipment, tailored specifically to this industry!



Absolutely!  The basic ad model is always free, which includes one photo and a short (200 characters) description of what you are selling.  However, we also offer additional ad models which allow for more photos and considerably longer descriptions, which would effectively improve your response ratio to any given ad.  Photos sell products!  Take a look at our various listing options, below:


NOTE: In lieu of paying directly for your ad listings (for premium style ads), you can also purchase Credit Packs which can then be used to pay for your ads.  Credits remain on your account until you decide to use them, and packs are available for bulk sellers for as low as .50 per credit!  This means your cost for each listing would be half of what you see in the image above!  Click here to learn view Credit Pack options.



No!  You can post ads for new equipment and supplies as well.



Sure!  In fact, we encourage it.  However, unless you provide some sort of special offer, package deal or discount to incentive potential buyers to purchase new (rather than used), you might find it difficult to compete against the great deals on used equipment.



We have dedicated an entire portion of the website to the Community Marketplace, which visitors to our website can access by clicking the new link at the top of any page:


Additionally, we have integrated widgets into various portions of the website, which will constantly showing random and Featured ads while users are browsing the DTG Print Solutions website – viewers can even search listings with our powerful search interface, from any page on the site!


Our website is a niche specialty site, focusing on a very specific portion of the market – our readers are exactly the people you are looking for to sell your used DTG printer to!  With over 20,000 page views in the last 30 days, we continue to grow our traffic to give you the greatest possibly exposure.  Remember, our viewers are highly targeted to this niche, so with your participation we can build the Community Marketplace to a thriving equipment listing in a short period of time.


bonus-free-creditsFor a limited time only, we are offering a FREE 30-Day “Enhanced” Listing credit to anyone with a new or used DTG printer to sell!  To receive your free credit, simply send an e-mail to info@dtgprintsolutions.com with your website account name and we will apply your credit within 24 hours!

Please make sure you have created an account on DTG Print Solutions (see link, below) and include your account name in the e-mail so we know where to apply your free credits!  Remember this offer is only for a limited time, so take advantage today and let us help you sell your printer!

Not currently a member of DTG Print Solutions?  Sign up today, for FREE!


A Call to Action: What Needs to Change Before DTG Printing Can become Reliable and Profitable

DTG Printing has been around for many years and it has certainly evolved quite a bit throughout the process.  In the early days of DTG, white ink printing wasn’t even possible and the general color gamut of CMYK inks was less than impressive. In a few short years, however, DTG printing has come a long way – white ink is mainstream (available on nearly every printer on the market) and the level of color output and print detail is absolutely stunning.  Visit any industry trade show across the country and you would find it incredibly difficult to not be impressed – it is not uncommon for the DTG booths to be absolutely loaded with potential buyers and interested parties, soaking up every second of the action as these high-tech wonders produce beautiful, full color prints on garments with what appears to be relative ease. Why then, do so many companies that adopt DTG printing wind up selling their machines within months of purchasing them (or sometimes, if they really like the abuse, they might keep battling their printers for a year or longer before they inevitably jump ship), often at a huge financial loss?  Part of the answer is staring us in the face while we stand there at the trade show, mesmerized by the visual print quality of the garment – the prints are just so incredible that we feel there is no way we can’t make money selling them!  Most of us would be hard pressed to find a screen printer would could even come close to competing with this level of quality.  However, what we often fail to notice is how excruciatingly long it takes to create a finished product, and they aren’t even showing all the steps at the trade shows!! Along these lines, I have compiled a simple list to explain what I feel must change in the DTG printing industry, before it can ever be accepted as a truly mainstream process.  After all, if small business owners can’t actually make money on it, then what’s the point??

DISCLAIMER: I am well aware that there are people out there having success in the DTG market.  These successful individuals are often the exception, rather than the rule.  I have noticed that people on the East coast seem to have slightly fewer issues with production (possibly due to higher overall humidity levels) but overall, more people fail out of DTG than are successful in the long run.  This article is meant to address the issues faced by most people who engage in the fine art of DTG printing, regardless of which printer they have selected.



To print in the highest quality settings using most standard 4880 based DTG printers (which, regardless of what the salespeople tell you, is virtually mandatory if you want to achieve the same level of quality you see at the shows) on a dark garment, assuming a standard sized print area (approximately 12″ x 12″), it could easily take 10 minutes per garment to complete the actual printing process!  While this does not include the time required to pre-treat each shirt prior to printing, it is important to remember that you will have plenty of time to perform this step while the machine is doing its thing….  In theory, the initial pretreatment process shouldn’t add any time to the overall process, just more labor – that is, unless you are one of those shops who pre-treats shirts prior to printing them (rather than doing it simultaneously with the print process). At approximately 6 units per hour for high-quality DTG printing, how can anybody really make a profit?  Dark garments are, as one might imagine, the most popular type of garment for most clients – you can try to talk them into white shirts (which are much easier to print, faster, cheaper, etc) but you can’t build a strong foundation if you are constantly trying to talk people into the “easier” option for you….  Sure, light garments (ie, no white ink underbase) are better for us as printers, but your potential clients really don’t care how much effort, time or money you put into the finished product – at the end of the day, they all want it cheap and they want it fast! Of course, some machines are faster than others, but I have personally owned everything from the Kornit to a multitude of Epson-based DTG printers in the last 10 years and the best I have been able to get in a real production environment, thus far, was about 12 units per hour on dark garments (and I was not entirely satisfied with the print quality, at those speeds).  Advancements in technology have allowed some companies to develop printers using larger, more industrial print heads – Ricoh is a common choice among manufacturers, but using larger print heads to lay down more ink in a shorter period of time can often compromise the overall print quality, since tiny droplets of ink are critical to creating to most subtle details and effects (just ask Anajet how that worked out for them).

Until we get to a point where the average DTG printer is capable of producing at least 24 units per hour (dark garments, at a standard print size), I don’t see most people being able to make a decent profit – especially when compared to many other print decoration options available which are faster and less expensive.

NOTE: You can approach DTG from the perspective of an embroidery business model – since each machine can only produce a painfully limited number of units per hour, it makes sense that you could scale your business appropriately by adding additional machines…  The problem with this, of course, is you wind up dealing with a multitude greater level of tech support and troubleshooting, so the scale factor is not easy to calculate.  Additionally, since the cost of each unit is general $15,000 or more, it would require an investment of about $150,000 to hit an hourly production rate of about 60 units per hour on dark garments – in the real world, you will always have a certain number of machines which are “acting up” at any given time, so really you wouldn’t even hit those numbers most of the time (even for such a staggering investment).


In the world of custom printed t-shirts, everyone is trying to save a buck.  Each and every client seems to want everything for nothing, so there is not much room for margins (especially when the client is ordering anything other than a single unit).  This becomes a major issue, of course, when you can only print 6-12 units per hour (which means you must amortize the cost of your general overhead and labor across a minimal number of finished product) and the cost of ink “per print” is often in the range of $2-3.  For the record, that number doesn’t even include the cost of the pretreatment, which must be added to the garment prior to printing. At one point my shop had 3 Neoflex DTG printers, which produced the absolute best quality at the time (compared directly to all the other models and brands I have owned) – since these 4880-based units we capable of producing some pretty big prints, we had lots of clients coming through the doors to take advantage of our print size capability.  While we were excited at first, our emotions soon turned to disappointment as we found the average cost of ink “per shirt” for these larger prints (generally 16″ x 20″) was easily averaging $8-10 per print!!  Oh, and at that particular print size (at the highest print quality) the total print time “per garment” was about 22-24 minutes.  At that rate and at those prices (assuming we had ZERO other expenses to contend with, aside from labor) we would have had to be charging around $34 per shirt to make our relatively low “net profit target” of $60 per hour. Of course, this would not have taken into consideration any misprints, quality rejects, shop overhead (like rent, electrical, phone and internet, etc) – the true number would have been north of $40 per garment, for a typical t-shirt…..  I suppose some markets do exist which would support this price for unique, one-off custom garments, but that market doesn’t include the clients that most of us tend to service on a regular basis.  If you can charge that much for a shirt, then more power to you!  We were trying to be competitive wholesale DTG providers, and it simply wasn’t feasible at those prices.  In fact, it was outright laughable.

In order for the average print shop to become competitive and profitable with DTG printing, the average cost “per print” really needs to fall in the .50-$1.50 range for an average size print on a dark garment.

NOTE: Many salespeople will try to tell you that their average cost “per print” is incredibly low – Brother even records print cost data across a broad range of users, allowing them to determine an allegedly accurate number for use in their sales and marketing documents.  However, these numbers generally include the cost of ink for small images (like left chest prints) as well as light garments – after all, it is a “total average” not a specific average…  At the end of the day, this is incredibly misleading since we must base our pricing on what it costs to do a standard size print – our profits don’t work in averages…. They work on a “per job” basis!


The production rates and ink costs provided assume that the DTG machine is actually working properly, without fail – in the real world (and I cannot emphasize this enough), I have never owned a DTG printer that actually worked all the time!  In fact, I don’t think it is uncommon to spend upwards of 30% of your time, on average, maintaining and troubleshooting your investment. Some companies offer excellent tech support service, while others tend to leave you high and dry after you make the purchase – even with excellent tech support, you will never receive the full-time, hands on assistance that most shops need in order to keep these machines running at peak performance, all the time.  Most DTG printer owners find themselves overnighting parts at an alarming rate, and spending as much time with their printers “opened up and in pieces” than actually printing garments for their clients…  Many issues are fairly common and don’t take too long to resolve, but this does not excuse the fact that DTG printers simply require significantly more maintenance and downtime than any other printing method or equipment I have ever seen.  Maybe 3D printing is the same way, but that is literally the only comparison I can make at this point in the game. When my shop finally stepped away (for now) from DTG printing, we had 5 DTG machines from different companies, as well as our own in-house tech support team dedicated to keeping them running.  Our main tech had been involved with many of the DTG printers we had owned, spent countless hours replacing parts and fixing major and minor issues, and had a solid working relationship with the primary tech support guys at the various manufacturers who had provided our equipment.  At the end of our run, there was not enough money I could possibly offer him to stay around and help me continue fixing my machines – he actually told me it was like trying to nail Jello to a tree, and he was “done with it”. A single Epson print head can cost between $400-700, depending on which model of printer you own (for the Ricoh, Brother and Spectra based machines, the cost is sometimes $1,000-4,000 per print head) – considering how shockingly easy it can be to destroy a print head (either through continuous use or by improper maintenance), this is a serious cost that must be considered in the long run.  This, of course, doesn’t take into account replacement capping stations, wiper blades, encoder strips, worn down plastic pieces, ink lines and lots more).

NOTE: I have owned at least 14 DTG printers in the last 10 years, and there has not been one single unit which has not required me to replace the print heads at least once!  This includes the supposedly “perfect” Brother GT-541 and the Kornit 932, as well as all other Epson based printers that have found their way through my shop over the years.  The inks we are running through these things have a much higher viscosity level than what the Epson print heads were designed for, and even the more industrial heads are subject to wear and tear from the TiO2 pigment that is added to the white inks to give them their opacity.  Additionally, all print heads are prone to drying out when they are not used regularly, so don’t even think about letting your investment sit idle – not even for a day!

Browse this website and you will find countless images from the last ten years, showing every single printer literally turned inside out and in various stages of disrepair – we are not unfamiliar with the technology and our issues cannot (to the dismay of so many salespeople, tech support people and equipment manufacturers) be simply attributed to fundamental “user error” – although this is the most common message you will hear in this industry, we cannot accept that we are the problem and the machines are so awesome….  That concept simply does not mesh with reality. Consider this – major companies such as CafePress and Zazzle are famous for their large, streamlined facilities and overall success in the industry; despite this, anyone behind-the-scenes will readily acknowledge the fact that at any given point, a certain percentage of their manufacturing stable is inoperable or receiving maintenance (scheduled or otherwise).  There is an overwhelmingly high amount of equipment turnover with larger DTG printing companies, whereas they will often invest huge sums of money into large numbers of new printers in an ongoing effort to find the “best machine out there”.  If these companies were completely satisfied with their chosen machines, we wouldn’t see them constantly switching between different brands.  Of course, I know they all have a certain number of reliable units which establish their “base foundation”, but having been on the sales side and having discussed various aspects of the technology with some of the big wigs in these companies, I can say with certainty that they are not completely content with any of the machines they are using.

If the DTG manufacturers want small business owners to succeed, they will design these machines to operate with minimal maintenance for much longer periods of time.  Even with OEM inks, most Epson printers are not intended to be printing constantly, so adding thicker ink to the equation isn’t doing us any favors in terms of reliability.  I should not have to do more than 10 minutes of maintenance per day (at most!) and there should be very little downtime on my DTG printers….  Additionally, I should be able to leave my printer idle for 2-3 days without worrying about whether I just cost myself $700 in a damaged print head.


Understand, I am not a “DTG hater” – in fact, I am probably one of the greatest supporters of this technology, having been involved since the very early days in a very public way and invested huge sums of my own money (as well as various investment capital) into trying to make it work in the real world.  When one machine didn’t hold up to expectations and hype, I tried the next in line, and so on until I finally couldn’t justify it any longer.  I am not beholden to any manufacturer or brand, and although I have many long standing relationships and close friendships within this industry, the primary purpose for my involvement is my own success in this niche and I would never continue to own a machine that was not truly making me money.  I want DTG printing to work in the real world, and I want to stop hearing stories about people who have invested their life savings into this business, only to be disappointed in the end. For now, I find myself licking my wounds and settling old accounts to try and recover the pieces from a long, difficult journey into this technology – having adopted several different processes which don’t involve DTG (dye sublimation being my favorite, so far), I am slowly rebuilding and getting things back on track.  As the industry continues to develop and grow, I find myself checking in constantly to see what the “next big thing” is, hoping and praying that we are getting closer to something that can be widely adopted (and retained) by the average business owner.  I expect that, at some point, I will be totally impressed and awe-struck at how far the industry has come, and I will take another stab at in-house DTG printing. Until then, however, I would like to offer an open challenge to all DTG equipment manufacturers out there:

We as a consumer base need more from you.  We need you to consider the points laid out in this article and we need to see some tangible progression in this industry.  Distributors are making a killing off of equipment sales commissions and ongoing ink sales, but the end user is often left disappointed and broke.  We cannot tolerate 6-12 unit per hour print speeds, and we certainly cannot shoulder the burden of $3-10 in ink for a single print – large sized prints should cost us about $3-5 in ink, max (with decent coverage).  Standard sized images, on dark garment, should use between .50-$1.50 in ink.  During a normal shift, while also considering any possible downtime and whatnot, we should be able to print 24-36 garments per hour on a single machine – anything less makes this more of a hobby than a serious business.  Finally, although we understand that there is only so much you can do about the cost of parts and whatnot, it is really important that our printers are able to function for an entire day without requiring us to do any heavy maintenance.  In fact, we really shouldn’t be opening up our machines (beyond opening the lid for a quick cleaning) more than once every few weeks (or months).  We don’t want to be constantly replacing parts, and although we love understanding every aspect of our machines we would rather not have to be certified experts and replace parts on a seemingly regular basis – we don’t have to deal with that sort of thing from our wide format printers / plotters, or from our dye sublimation equipment, so why should we have to put up with it for DTG?  If things still aren’t completely up to par, be honest about it – don’t tell us to expect 15 prints per hour, when we both know we should probably expect more like 6-8…  At the end of the day, it will help us better determine if this business is really for us, and if we choose to dive in then we can at least prepare for what is in store for us and create a business model that is appropriate for this process.  DTG printing has come a long way and we are pleased by this, but there are still too many people losing their asses after a relatively short period of time trying to make it work.  Don’t just promise us more, but deliver more – actions speak louder than words, and we can’t wait to see this technology evolve into something entirely practical and profitable.

PS – Oh, and don’t try to pull that nonsense about how “when it becomes too easy, everybody including Wal-Mart will be doing it” – dye sublimation is easy, as is standard vinyl printing and plotting (relatively so, of course)…  However, we don’t see them destroying the small business market in these other fields – sure, there will always be big corporate competition, but that doesn’t mean we can’t be just as competitive with some reliable and affordable equipment and inks.

If you agree with this, please comment or share this article!  We are spending a lot of money to help develop this industry, so we should definitely be getting more out of it, at this point.  The important people are reading it, and the more attention we can give (and support), the more likely they will be to take it seriously.  Don’t be content acting as a paying guinea pig for the equipment manufacturers – demand more from this industry, so we can all get more out of it.

Nonstop Neoflex Production – One Hour in 15 Minutes

Many people ask us about the potential production rates they can expect with their DTG printer…. While the answer to this question may be difficult to pinpoint without understanding your machine capabilities, intended print resolution, production setup and other factors, we can at least show you a one-hour snippet of production from our very own DTG production facility.  This video was released awhile ago, but it shows a full one-hour production cycle, uninterrupted, including the entire pretreat / print / heat press cycle.

This video shows only one employee working on production (me) using on only one of our DTG printers, and is sped up to 4x normal speed to ensure you don’t get too bored during the process…  We are using the following production setup for this video:

  • PRINTER: Neoflex DTG printing system by All American MFG (based in Philly, PA)
  • RIP: Kothari DTG RIP (branded as NeoRIP PRO)
  • PRETREATMENT: ViperONE Automatic Pretreatment machine
  • PRINT SETTINGS: As always, we are printing in Hi-Resolution mode (the only mode we feel comfortable offering to clients for top-quality DTG printing)
  • GARMENT COLOR: We are printing on dark garments, using the full three platen setup available on the Neoflex DTG printers

Average production speeds (with our configuration) are approximately 6 finished garments per hour on one machine.

FREE Articles for YOUR Website!

We are happy to announce that we are making many of our most popular blog posts (from our printing company website) available to the general public for use on any website.  If you are involved in the Direct to Garment (DTG) Printing business, it helps to offer your potential customers as much information as possible.  By addressing their concerns early, you will be able to avoid many potential miscommunications with your clients during the actual order process.

Feel free to use the FREE resources available on this website, including the FREE Articles for YOUR Website list to enhance your own customer experience for your DTG printing company.

Over the decade we have been running our DTG printing business, we have developed a number of articles which help better explain certain facets of the business to new clients.  For your convenience, we are making some of these articles available to you, for your website – feel free to copy the articles and paste them on your own website to help further educate your customers.  All articles listed below are available to use and edit as you see fit – please let us know if you have any questions.

INSTRUCTIONS: Start by copying and pasting the text of your selected article to your own website.  Once you have pasted the text, be sure you replace all of the company name and contact information with your own, and carefully review each article to adjust pricing examples and other information to fit your own business model.  Don’t be afraid to make some changes!

NOTE: Your are free to use the text from these articles as you see fit, but the images are copyrighted material and may not be reused without our express written consent.  Please show your customers what you are capable of producing by printing and photographing your own custom products to go along with these articles.  The images currently presented represent our efforts and hard work, and it is important to show off what you can do. 

Aside from that, have fun with it!  These articles should give you a good starting point when building your DTG printing website, and will allow you to more thoroughly cover your back-end when people take issue with certain caveats of Direct to Garment Printing.


We hope you enjoy these free articles to help jump start your own independent DTG printing website – if you have any questions or comments, feel free to contact us or make a comment at the bottom of THIS PAGE!

More great articles will be coming soon, so check back frequently to ensure you have all of the most up-to-date information for your company website!