Troubleshooting Common Issues in Direct-to-Garment Printing (DTG)

Direct-to-Garment (DTG) printing is known for producing high-quality, vibrant prints on fabric, but like any printing method, it can have its challenges. Whether you're new to DTG or an experienced printer, encountering problems during production can be frustrating. However, understanding these common issues and knowing how to troubleshoot them effectively will save you time, reduce waste, and ensure that your final products meet customer expectations. Below, we'll walk through the top five common DTG printing problems and provide detailed solutions to help you resolve them.

1. Poor Ink Adhesion

One of the most frequent issues in DTG printing is poor ink adhesion. When the ink doesn’t properly stick to the garment, it can lead to faded or patchy prints.

Cause:

• The most common cause is inadequate pre-treatment, which is essential for proper ink bonding, especially on dark-colored garments.

Solution:

• Correct Pre-Treatment Application: Pre-treat the garment with the recommended amount of solution. Using too little can result in weak ink adhesion, while over-applying can create blotches. If you're using a pre-treatment machine, ensure it’s calibrated for even distribution.
  
  
• Thorough Pre-Treatment Curing: Once pre-treated, the garment must be dried properly with a heat press to ensure it's ready for printing. The fabric should be dry to the touch before you proceed to print.
  
  
• Test Prints: After pre-treatment, always perform a test print to verify ink adhesion and make any necessary adjustments.

2. White Ink Not Printing Properly

White ink issues, such as streaking, fading, or uneven coverage, are common in DTG printing. This is due to the thicker consistency of white ink, which requires special attention.

Cause:

• White ink tends to settle in the ink lines and cartridges, leading to clogged nozzles or improper ink flow.

Solution:

• Daily White Ink Maintenance: White ink needs regular agitation to prevent settling. Be sure to shake the white ink cartridges or activate the printer’s automatic ink circulation system.
  
  
• Nozzle Checks: Perform a nozzle check before each printing session to ensure all nozzles are firing correctly. This will help prevent streaking or missing areas in your design.
  
  
• Environmental Control: White ink is sensitive to changes in humidity. Keep the printing area’s humidity level between 45%-65% to prevent ink from drying out and clogging the print head.
  
  
• Proper Storage: Store white ink cartridges in a cool area and agitate them regularly to prevent settling.

3. Washed-Out Colors

If your prints appear dull or faded right after printing or after curing, this is usually a sign of incorrect pre-treatment or improper print settings.

Cause:

• Insufficient pre-treatment or incorrect printer settings can result in colors that lack vibrancy and depth.

Solution:

• Ensure Proper Pre-Treatment: Make sure the garment has been evenly pre-treated, especially for darker fabrics. The pre-treatment layer is crucial for enhancing color vibrancy. A pre-treatment machine like the Viper MAXX can greatly reduce many issues caused with pre-treatment.
  
  
• Adjust Print Settings: Check that your DTG printer settings are optimized for the fabric type. This includes using the correct color profiles and ink settings. Increase the ink density for more vibrant prints if necessary.
  
  
• Proper Curing: Curing the printed garment at the right temperature and time (typically 320°F for 90-120 seconds) ensures the ink bonds properly to the fabric. Incorrect curing can cause colors to appear washed out.
  
  
• White Underbase: For dark garments, ensure the white underbase is applied properly. This base layer helps the color layers pop, giving you vibrant, eye-catching results.

4. Grainy or Fuzzy Prints Due to Loose Garment Fibers

Grainy prints can happen when loose fibers on the garment's surface interfere with the ink application, particularly on fabrics with rough textures or loose weaves.

Cause:

• Loose fibers on the fabric surface can lift the ink, leading to a grainy or uneven print.

Solution:

• Garment Selection: Choose garments with a tighter weave or ringspun cotton to avoid grainy prints. These fabrics tend to produce a smoother print result.
• Heat Pressing: After pre-treating, press the garment for a few seconds before printing to flatten the fibers and create a smoother surface.
• Lint Rolling: Before applying pre-treatment, use a lint roller to remove loose fibers from the garment. This simple step ensures that the surface is smooth and ready for printing.

5. Ink Cracking After Washing

Nothing is more frustrating than creating a beautifully printed garment, only to have the ink crack after washing. Cracking reduces the quality and durability of the print, impacting customer satisfaction.

Cause:

• Cracking is often caused by improper curing or applying too much ink.

Solution:

• Cure Correctly: Ensure you’re curing the garment at the correct temperature (320°F) and time (90-120 seconds). Too low a temperature or short curing time can prevent the ink from bonding fully to the fabric.
• Avoid Over-Inking: Over-applying ink can create thick layers that are more prone to cracking. Use the recommended ink settings for the garment type and adjust as needed to avoid thick layers of ink.
• Wash Tests: Perform wash tests on printed garments to assess durability. If cracking occurs, revisit your curing and ink application processes.

Final Thoughts

DTG printing offers a great deal of flexibility and quality, but like any production method, it can present challenges. By understanding common issues and how to troubleshoot them, you can minimize downtime, reduce waste, and improve the overall quality of your prints. Regular maintenance, proper pre-treatment, and using the correct printer settings are key to resolving most problems, allowing you to achieve consistently great results.


Reach Out to Millcraft for Your Direct-to-Garment Consumables

At Millcraft, we know that quality consumables are essential to producing high-quality DTG prints. Whether you need pre-treatment solutions or inks, using premium products can help you avoid many of the common issues discussed above and improve your overall printing quality. Our team of experts is here to guide you in selecting the best DTG consumables for your needs and ensuring your production runs smoothly.

If you're facing problems with your DTG printing or simply want to optimize your process with the best materials on the market, Millcraft has everything you need. From expert advice to a comprehensive range of consumables, we are dedicated to helping you achieve great results with every print.

Contact Millcraft today to learn more about our Direct-to-Garment consumables and how we can grow your printing business! Just Ask.