In the latest episode of Let’s Get Printing, host Zack Dewhurst, owner of Print Phase, sat down with Brandon Mills, founder of Total Promotion Company, to discuss the explosive impact of DTF (Direct-to-Film) printing on the custom apparel industry. This episode dives deep into how DTF has transformed the apparel decoration space, lowered entry barriers, and created new opportunities for businesses of all sizes. Here’s a breakdown of key insights from the conversation that you don’t want to miss.
The Game-Changing Rise of DTF Printing
DTF printing has quickly become one of the most talked-about technologies in the garment decoration world, and for good reason. According to Zack and Brandon, DTF has “eaten into almost every other decoration method,” including screen printing and embroidery. The reason? It’s a digital printing process that provides vibrant, high-quality results on various fabrics at a much lower cost. Here’s why DTF is shaking things up:
- Accessibility: You can either invest in your own DTF printer or outsource the printing.
- Lower costs: DTF allows for smaller runs without high setup fees.
- Flexibility: DTF prints work on a range of materials, from cotton to polyester.
From Screen Printing To DTF: Brandon’s Journey
Brandon started his business right before the pandemic hit, but even in these challenging times, he saw DTF as a golden opportunity to evolve his company. Initially, he explored other printing methods like screen printing, sublimation, and DTG (Direct-to-Garment). However, each method had limitations—screen printing required manual labor and long setup times, sublimation only worked on white polyester, and DTG required pre-treating cotton garments.
That’s when he discovered DTF. He invested in a 24-inch DTF printer and quickly realized its potential to solve the issues he had encountered with other methods. Over time, he has transformed Total Promotion Company into a leader in DTF printing, providing both apparel and transfer services for other print shops.
Overcoming The Challenges Of Early DTF Technology
While DTF printing offers significant benefits, the journey hasn’t been without its challenges. As Brandon explained, the early days of DTF were akin to the “Wild West,” especially with most of the equipment coming from China. Early adopters had to deal with unreliable printers, inconsistent ink quality, and the lack of proper manuals or technical support.
Brandon shared that he went through 13 print heads in his first year—an expensive and frustrating experience. However, through persistence and a commitment to R&D, he optimized his process and now runs one of the most reliable DTF operations in the industry. His advice? Invest in quality ink, maintain your equipment, and create a climate-controlled environment for your printers.
The Evolution Of DTF Technology: What’s Next?
As the conversation progressed, Zack and Brandon touched on the future of DTF technology. One of the biggest upcoming trends is powderless DTF, which eliminates the need for adhesive powders, further simplifying the process. Brandon believes that DTF is still in its early stages, but innovations are rapidly improving quality and lowering costs. Eventually, we might see compact, consumer-grade DTF printers sold at retail stores like Walmart—much like the evolution of sublimation printers.
Why DTF Has Become The Industry Standard
The podcast highlighted why DTF printing is rapidly becoming the go-to method for custom apparel businesses. Beyond its affordability and ease of use, DTF has democratized the industry. Even small shops or hobbyists can now offer high-quality, full-color prints without the need for expensive equipment or large production spaces. Some key benefits include:
- On-demand printing: No need to keep large inventories of printed apparel.
- No weeding: Unlike vinyl or HTV, DTF transfers don’t require tedious weeding of designs.
- Durability: DTF prints are known to withstand multiple washes without cracking or fading.
The Importance Of A Reliable Supply Chain
One recurring theme in the episode was the importance of a reliable supply chain. Both Zack and Brandon emphasized that the key to success in DTF printing lies in having consistent access to high-quality consumables—inks, films, and powders. Any disruption in the supply chain can affect production quality and timelines, which is why it’s crucial to work with trusted suppliers.
Brandon’s company, Total Promotion Company, has become a trusted source for DTF transfers in the Las Vegas area and beyond, thanks to his commitment to providing consistent, high-quality products. Whether you’re just starting out in the industry or looking to scale your operation, his advice is simple: “Do your research and invest in quality from the beginning.”
Final Thoughts: Is Direct To Film Right For Your Business?
As the episode came to a close, Zack and Brandon reflected on why DTF printing might be the future of custom apparel decoration. With its ability to produce high-quality, cost-effective prints on demand, DTF is a game-changer for shops of all sizes. If you’re tired of the limitations of traditional printing methods or are looking to streamline your production process, DTF could be the solution you’ve been waiting for.
