PRODUCT ION

Direct-to-Garment Inkjet Devices: Technology Update

With average run lengths dropping, having the capability to print small quantity custom designs, at higher margins, is an attractive feature to the thousands who have adopted direct-to-garment inkjet technology in their shops.

Fast production times, high-quality, full ink droplet. Siemens introduced the first with producing a four-color process, color images, unlimited customization and drop-on-demand inkjet printer, the PT-80, photographic print that actually looks ease of use are just some of the benefits in 1977. good and generates a profit when using associated with direct-to-garment digital Today, direct-to-garment inkjet printers screen . Digital equipment also has printing. This article explores direct- are being used by apparel decorators who less space requirements and is a low-cost to-garment inkjet technology and the are eager to gain additional market share. investment when compared with screen workflow necessary to produce a digitally With average run lengths dropping, having printing, which needs a larger amount of printed garment, discussing highlights of the the capability to print small quantity valuable floor space and potentially tens of technologies embedded in the latest devices custom designs, at higher margins, is an thousands of dollars in equipment costs. and recent trends in their development attractive feature to the thousands who Let’s not forget the labor and material cycle. You’ll find a direct comparison of have adopted direct-to-garment inkjet costs associated with making, cleaning screen versus digital production costs and technology in their shops. and reclaiming screens, not to mention the potential profit margin as well as the next Today’s consumer wants a product that solvent usage and mess that is generated. wave of technological developments that expresses his or her individuality. Fashion Digital produces little mess, requires no will impact . surveys indicate that a high percentage of screens, uses little solvent and could save is a non-contact method young adults alter their clothing in some facilities time by avoiding setup delays or of printing, in which droplets of ink are way, reaffirming the notion that everyone downtime caused by screens. jetted through a small aperture (nozzle) to wants to be different. Digital technology Digital also thrives when variable data a specific position on a media to produce thrives in this context because of its ability is a job requirement. Names, numbers and an image. The first inkjet printer was to economically produce one or two prints design variations all are easily handled developed by Siemens in 1951, based on as compared with , which with digital technology. But as with any the continuous inkjet method whereby a involves the laborious task of making technology, digital has its disadvantages. piezoelectric crystal vibrates and causes a screens and setting up presses to produce For large-run lengths, digital is slower liquid stream to break into droplets. just one print. than screen printing, and can cost a Direct-to-garment inkjet devices use what company more to produce a job. The is known as drop-on-demand piezoelectric Advantages and Disadvantages of break-over between digital and screen technology, which produces ink drops by Direct-to-Garment Inkjet depends on each shop, applying voltage to a piezoelectric crystal Many find the biggest advantage of but reports of printers and causes it to vibrate. The mechanical digital technology is its ease of use in using direct-to-garment motion of the piezoelectric material creates producing vivid, full color photographic devices to produce pressure in the ink reservoir, and ejects an images. Gone are the challenges associated thousands of prints are ▲ By Johnny Shell, Vice President – Technical Services, SGIA

Visit SGIA at SGIA.org SGIA Journal ■ Third Quarter 2007 11 becoming quite common. Obviously, the any color of fabric. But the disadvantages lead-time with a high-volume order will include longer print times, increased ink be a considerable factor when choosing a cost as compared with a digital print on printing technology. a light fabric and added workflow and Digitally printed ink costs also are maintenance steps. Another issue with considerably higher than those for screen, white ink is the settling properties. with prices ranging from a few pennies One might think white ink is no different to more than $2 per print. With screen, than any other used in inkjet printers. In average ink costs per print are usually less reality, white ink presents many challenges than 50 cents, with many at 25 cents or less. for developers, especially when printing on Digital also is not capable of producing the fabric. Industry pioneers in the graphics necessary abrasion resistance required industry were the first to use white ink in for athletic printing, nor is it capable of wide-format, UV-curable inkjet printers. printing special effect inks such as glitter Because UV-curable inks are aggressive and or gels. Matching Pantone or custom-spot extremely durable, they do not have media color can also be challenging because restraints other ink systems have. direct-to-garment devices use ink sets Once this realization caught on, we based on cyan, magenta, yellow and black started to see prints on unique substrates (CMYK). While many Pantone colors are such as stone, wood, leather, ceiling tile and achievable in the CMYK color space, a many others. As the saying goes, necessity considerable percentage is not. is the mother of invention. As you can Figure 1: Once printed, the ink must be set using either a heat press or a conveyor dryer. With most available direct to garment imagine, printing an image on stone would not have the same color and brightness as printing an image on white paper. Thus, the need for white ink was born. But developers quickly realized only certain white pigments would provide the necessary performance and opacity needed for their printers. Titanium dioxide is the most widely used white pigment because of its brightness, high-refractive Figure 2: Here we see an encoder strip at 100% (far left). The center image shows a new encoder strip. index and effectiveness as an opacifier. The far right image shows an encoder strip that is contaminated with ink overspray from the nozzles. However, titanium dioxide pigment is This can cause the printer to lose its frame of reference. harder to keep suspended in a solution devices, printing on dark shirts with because of its weight. If the pigment falls out white ink entails additional tasks of pre- of suspension, it is difficult to return the ink treating the garment, extra print passes to its original, homogenized state. The most and more regular maintenance procedures. common cause of this is when a printer is not Pre-treating a garment involves using a operated for quite some time. Most printers solution that is applied through a high- offering white ink have adequate movement volume, low-pressure (HVLP) spray gun that is naturally generated by the machine or via automatic-spray equipment, which is to keep the pigment in suspension. If the included on board the printer or as a stand- machines are not operated for more than a alone unit. The application consistency few days, the pigment will begin to fall out and pretreatment’s repeatability, when of suspension, which can cause problems. applying it manually with a spray gun, is Formulators are regularly introducing very important. Applying too much will newer versions of white ink that inhibit affect how well the image holds up in a pigment separation, so it is a problem every laundry cycle. Applying too little will cause leading company faces. the white ink to fall down into the dark Another obstacle with titanium oxide fibers of the shirt, instead of sitting on top is its aggressiveness on piezoelectric print to build the necessary opacity. The gun’s heads. White ink requires a bit more spray pattern can also affect the resulting involvement from the operator to ensure print, so keep the nozzle properly adjusted the device will function properly. A proper and cleaned to avoid spurts. maintenance schedule should be in place Using white ink will virtually double and followed to extend the life of the print the total print time for each shirt. White head. All inkjet printers will malfunction if ink is printed separately in the initial print they are not maintained and cleaned on a Figure 3: Print heads are the lifeblood of any device. pass, which deposits the under-base. This routine basis, no matter who manufactured Shown here are the print heads from a Brother print pass is followed by a second pass the device. GT541 (top) and an Epson 2200 based unit. All colors are jetted through the Epson head while that deposits the color, and sometimes a As mentioned, many direct-to-garment the Brother unit requires one head per color. highlight white. The big advantage of white devices are capable of printing white ink. ink is having the capability to decorate However, one manufacturer’s approach

12 SGIA Journal ■ Third Quarter 2007 Visit SGIA at SGIA.org was to adopt a technique that has long material deforms under electrical voltage, been used in screen printing. The Mimaki an acoustic-pressure wave is generated, Digital equipment also has GP604D uses discharge ink, which contains which affects the ink volume in the a chemical agent that works to remove the pressure chamber of the head. This wave less space requirements and is dyes in the shirt and return it to its pre- moves through the ink in the reservoir and dyed state. Color can then be printed in the toward the nozzle, eventually causing an a low-cost investment discharge areas. Discharge produces a print ink droplet to be ejected. with a much softer feel as compared with One aspect of digital printing that when compared with screen screen or digitally printed dark garments. every user should understand is that To achieve the best results with discharge the print head is a consumable and will printing, which needs a larger ink, garments must be made of natural need to be replaced. The print head’s life fibers (100 percent cotton) and dyed using expectancy will vary based on the device, amount of valuable floor space a reactive dye. Many suppliers brand their how frequently it’s used and how well it’s garments as dischargeable, but it’s always maintained. Plan to replace at least one and potentially tens of good to test them. Also, it’s important that head per year, even if a head does not the garments not be over-dyed as the results actually fail. Replacement costs for print thousands of dollars can be unsatisfactory. Over-dyeing occurs heads will vary among manufacturers, when fabric is re-dyed to another color. but the average cost is $300 to $1,000. in equipment costs. This often happens because of a shortage Most heads fall in the lower-end of the for a certain fabric color or, in many cases, range. Industrial heads, manufactured by because quality control rejected the fabric Spectra and Xaar, fall in the upper price color. The rejects are then over-dyed with range. Lower-priced print heads will need

Figure 4: This photo shows an Epson print head. Note the tiny nozzle openings as compared to the lead of a pencil (far left) and a close-up (far right). black. When using discharge with over- to be replaced more frequently while more dyed garments, the discharge ink may costly print heads will require less frequent discharge the secondary black dye and replacement. reveal a phantom color underneath it. Discharge also contains formaldehyde. Print Platforms Although it sounds bad, it isn’t as harmful as While a complete listing of direct-to- you may think. The formaldehyde content garment inkjet printers is included in Table is used in extremely small quantities, and 1, there are several distinctions among washes out of the shirt in the first washing. the devices you should know. The most In the past, many people were fearful prevalent is many devices are based on an because of the formaldehyde’s presence but Epson print engine or Epson print heads. much progress has been made to make this A print engine is the underlying device ink as safe as possible. that has been modified into a garment printer. Common Epson print engines used Print Heads in direct-to-garment devices include the The print head is the heart of an inkjet R1800, 2200, 7800 and 4800, which are printing system. It contains either a single used in printers such as the T-Jet 3, Flexi- channel (jets only one color) or multiple Jet and DTG Kiosk. channels (jets more than one color), and Other device manufacturers integrate causes an image to be transferred to the a pre-existing Epson print head into their substrate. Piezoelectric drop-on-demand device and source the remainder of the (DoD) print heads are used exclusively in printer components. These devices include direct-to-garment devices. Piezoelectric the Mimaki GP604 and Anajet FP-125. print heads use crystalline materials, Epson has been manufacturing print heads which have the ability to deform when ever since its first affordable piezoelectric Figure 5: Many devices offer the capability to print high-electric fields are applied. As the head was introduced in 1993. In 1997, the same image to either light or dark garments.

Visit SGIA at SGIA.org SGIA Journal ■ Third Quarter 2007 13 Epson introduced a print head design that colors, as the driver assumes a standard ink improper margins. Printing may even stop dramatically simplified the fabrication set is being used. if the encoder strip is severely contaminated process and reduced overall consumer with dust, lint or ink. costs. This enabled engineers to work on Curing As previously stated the print head is miniaturizing nozzles and improving print Properly curing the ink ensures a a consumable and will periodically need resolution and quality, bringing the price durable image that will withstand common to be replaced. Depending on the device, point of a piezo based printer within the laundering practices. If the ink is not this procedure is not complicated, and can affordability range for many consumers. properly cured, the wash fastness will suffer usually be done in less than 30 minutes. Epson is well known for the image quality greatly. Cure temperatures are specific to The most common cause of print head and resolution its products produce. Epson’s the ink being used, so be sure to follow the failure is a lack of following manufacturer- components are used in many small- and manufacturer’s recommendations. Generally, recommended maintenance. Leaving devices wide-format inkjet devices, which further cure temperatures for many available devices turned on to avoid startup head cleanings, in expand the company’s reputation. hover at 176.7°C (350°F), with cure times many cases, causes the ink to dry and clog The last device group falls into what ranging from 30 to 60 seconds or more. nozzles. The irony here is that more ink is I call the “ground-up builds,” which are Cure times of two minutes or more may wasted in trying to unclog the nozzle than printers that have been designed using be suggested by the manufacturer when would be wasted in a normal head cleaning available components and a mere concept. printing with white ink. at machine startup. Turning machines off All printers offered by Kornit Digital and Variability in the degree of cure can overnight ensures the head is properly Brother are considered ground-up builds. be caused by several factors, especially seated in the capping station to keep ink in Printers in this category are robustly when printing with white ink. Common the head liquefied, avoiding nozzle clogs. engineered and come at a higher price considerations to determine proper cure Another misconception is machines than Epson-based machines, with equal are the number of print passes, amount of can be used only when they are needed capability and print size. Conversely, white ink coverage and total ink coverage for an order. In reality, direct-to-garment devices based on Epson print engines use in the image. To ensure proper cure, a inkjet devices perform better when they pre-existing document printers, which are wash test is recommended to identify any are continuously printing. If left unused for modified to print on apparel using water- problems in the degree of cure. several days, the ink can dry in the nozzles based pigmented textile ink. of the head and ink supply lines, and the Maintenance — It’s Not Plug-n-Play! pigment in the reserve ink in bulk storage Workflow: Light vs. Dark The chief factor many owners tanks can begin to fall out of suspension. Many devices allow for printing on white underestimate is the amount of routine All manufacturers recommend you perform or light shirts by using a standard set of maintenance that is required to keep direct- at least one head cleaning if the machine inks and a print driver. This method allows to-garment inkjet printers functioning. will sit idle for several days. For longer the user to choose the printer in the print All manufacturers have daily, weekly and periods, manufacturers offer a flushing dialog box, similar to selecting a particular monthly routine maintenance schedules solution or cartridges that will flush the printer on an office network. When using for their devices, which should be strictly ink out of the supply lines and print head this method, the user creates an image followed. When maintenance is not to avoid clogging. When the machine is within a preferred graphic application and performed as recommended, machines will needed, the ink is replaced and several head selects “Print.” As standard ink sets such as malfunction, possibly causing misprints. cleanings are done to recharge the supply CMYK or CMYKlclm are used, the image Furthermore, parts may need to be replaced lines and print head with ink. While this is accurately reproduced on the garment prematurely because of a lack of care and seems like a time-consuming task, it in no with little operator intervention. However, maintenance. way contends with the headache you will when printing to dark garments, white Common maintenance tasks include suffer by not doing this. ink is introduced and requires workflow cleaning the capping station and encoder adjustments. strip, greasing guide rails, replacing print Time and Money: Screen vs. Digital When printing with white ink, the print heads and servicing the waste ink tank. When evaluating both technologies from driver option usually isn’t possible. The The capping station on many devices is a time and money perspective to determine user typically works with a manufacturer used to collect waste ink while the heads which is most cost effective, the following RIP or secondary software application are being cleaned. The capping station breakdown is intended to serve merely as that generates a white under-base and also may serve to seal the head when the an example. Individual results will vary highlight white for printing onto dark machine is turned off to hinder ink drying based on your market, local and regional fabrics. The RIP then communicates with in the print head’s nozzles. Epson-based conditions and your business’ operating the printer so that only the white head or machines also include a wiper blade near expenses. An important fact to realize is channels in a head fire during the under- the capping station, which periodically digital technology can meet certain market base pass. Additionally, the RIP dictates the needs to be replaced. needs in a profitable manner. highlight white that will be printed when The encoder strip is a semi-clear strip, Let’s assume we have an order for 24 the CMYK colors are also being printed. usually located behind the carriage rod that shirts that need a full-color, full-chest When printing a light or white shirt with supports the print head. The encoder strip’s print that will sell for $15 each, totaling a device using white ink, the operator may role is to help the print carriage accurately $360. Using screen printing, the total need to use the manufacturer’s RIP or keep track of its position as it traverses production time for this job would be software, again, so that only the proper along the carriage rod. Dust or ink can between three to four hours, and includes channels in the head fire during printing. accumulate on the strip, causing problems the tasks and approximate completion If using the standard print driver, white such as mis-registration among printed times in Table 2 (Page 16). The listed ink would be printed along with the other colors, gaps in the printed image and information assumes the screens are

14 SGIA Journal ■ Third Quarter 2007 Visit SGIA at SGIA.org Direct-to-Garment Inkjet Devices Company Model Print Head MFG Colors Max. Speed Price Web site Engine Image Size All American Flexi-Jet Standard Epson 4800 Epson (1 head) 5 (CMYK + White) 15 x 20 in. 10 x 13.5 in = $17,995 www.screenprintsupply.com 60 seconds Flexi-Jet Extended Epson 4800 Epson (1 head) 5 (CMYK + White) 15 x 20 in. 10 x 13.5 in = $21,995 www.screenprintsupply.com 60 seconds Anajet FP-125 Anajet Epson F-Mach 8 (CMYKx2 or 12.5 x 16 in. 10 x 12 in = $12,950 http://anajet.com (1 head) CMYKWWWW) 65 seconds Azon Micro TEX Epson 2200 Epson (1 head) 7 (CMYKLcLmLk or 12 x 18.5 in 8.25 x 11.5 in = $10,100 www.azonprinter.com CMYKWWW) 50 seconds Micro TEX Pro Epson 4800 Epson (1 head) 8 (CMYKx 2 or 16.5 x 23.5 in. 8.25 x 11.5 in = $14,000 www.azonprinter.com CMYKWWWW) 40 seconds Brother GT541 Brother Brother (4 heads) 4 (CMYK) 14 x 16 in. 12 x 12 in = $20,000 www.brother-usa.com 50 seconds Kornit 932DS Kornit Spectra (8 heads) 8 (CMYKWWWW) 14 x 16 in. 14 x 18 in = $75,000 www.kornit-digital.com 72 seconds 931 Kornit Spectra (8 heads) 4 (CMYK 16 x 20 in. 4.75 x 11 in. = $170,000 www.kornit-digital.com 35 seconds 931DS Kornit Spectra (8 heads) 8 (CMYKWWWW) 16 x 20 in. 4.75 x 11 in. = $205,000 www.kornit-digital.com 35 seconds MakkiUSA Twister 6 Epson 4800 Epson (1 head) 8 (CMYKx2 or 15 x 27 in. 12 x 10 in. = $80,250 www.makkiusa.com CMYKWWWW) 38 seconds Twister 8 Epson 4800 Epson (1 head) 8 (CMYKx2 or 15 x 27 in. 12 x 10 in. = $116,500 www.makkiusa.com CMYKWWWW) 38 seconds Twister 12 Dual Epson Epson (2 heads) 8 (CMYKx2 or 15 x 27 in. 12 x 10 in. = $156,000 www.makkiusa.com 4800 CMYKWWWW) 19 seconds MicroLogica ProJet Epson 4800 Epson (1 head) 8 (CMYKx2 or 17 x 27 in. 12 x 10 in. = $14,995 www.makkiusa.com CMYKWWWW) 38 seconds MiniLogica ProJet Roland, Mutoh, Epson 6-16 White Ink 33 x 60 in. 12 x 10 = $55,900 www.makkiusa.com or Mimaki Ready 60 seconds - $59,900 Mimaki GP604 Mimaki Epson 4 (CMYK) 16.5 x 24 in. 10 x 12 in. = $25,000 www.mimakiusa.com 4 minutes GP604D Mimaki Epson 4(CMYK) + 16.5 x 24 in. 10 x 12 in. = $25,000 www.mimakiusa.com Discharge 4 minutes MS Italy MS Zero Epson 2200 Epson 7 (CMYKLcLmLk or 12 in. x 49 ft. 8.25 x 11.5 in = $11,142 www.msitaly.com CMYKWWW) 45-75 seconds MS One Epson 4800 Epson 8 (CMYKx2 or 17 in. X 49 ft. 8.25 x 11.5 in = $16,305 www.msitaly.com CMYKWWWW) 30-60 seconds MS Two Epson 9800 Epson 8 (CMYKx2 or 17 in. x 49 ft. 8.25 x 11.5 in = $42,121 www.msitaly.com CMYKWWWW) 45-75 seconds OmniPrint Texjet Epson 4800 Epson 8 (CMYKx2 or 16.4 x 24.2 in. 8.5 x 11 in. = $19,799 www.omniprintonline.com CMYKWWWW) 60 seconds SanWave SWI-A2 Epson 4800 Epson 8 (CMYKx2 or 17 x 22 in. 17 x 22 in. = $12,500 www.swi-usa.com CMYKWWWW) 3 minutes

Sawgrass Direct Advantage Epson 4800 Epson 4 (CMYK) 15 x 18 in. 12 x 12 in. = $13,995 www.sawgrassink.com 60 seconds SWF DTG Kiosk Epson 2200 Epson 7 (CMYKLcLmLk or 12.72 x 21.72 8.5 x 11 = $10,995 www.dtgamerica.com CMYKWWW) in. 1 minute, 50 seconds DTG Kiosk HM1 Epson R2400 Epson 8 (CMYKx2 or 12.72 x 21.72 11 x 17 in. = $16,995 www.dtgamerica.com CMYKWWWW) in. 50 seconds Eclipse D1 Epson R2400 Epson (2 heads) 5 (CMYK + White) 12.5 x 21.25 8.25 x 11.5 = $28,995 www.dtgamerica.com x 2 in. 78 seconds DTG Xpress Epson 9800 Epson 7 (CMYKLcLmLk or 24 x 60 in. 44.8 x 100 in. = $44,995 www.dtgamerica.com CMYKWWW) 10 minutes DTG Bullet Epson 7800 Epson 7 (CMYKLcLmLk or 44 x 98 in. 12 x 12 in. = $59,995 www.dtgamerica.com CMYKWWW) 1.5 minutes US Screen Fast T-Jet 3 Epson R1800 Epson 7 (CMYKLcLmLk or 12.5 x 22 in. 12 x 12 in. = $16,995 http://screenprinters.net Print & Inkjet CMYKWWW) 60 seconds Technology Fast T-Jet Blazer Epson 4800 Epson 8 (CMYKx2 or 16.5 x 48 in. 12 x 12 in. = $24,995 http://screenprinters.net CMYKWWWW) 45 seconds Fast T-Jet Jumbo 2 Epson 7800 Epson 8 (CMYKx2 or 16.5 x 48 in. 12 x 12 in. = $44,995 http://screenprinters.net CMYKWWWW) 45 seconds Fast T-Jet ProHV DuPont Artistri Spectra Nova Q 8 (CMYKROGB or 16.5 x 48 in. 12 x 12 in. = $240,000 http://screenprinters.net (16 heads) CMYKROGB + White) 45 seconds

Visit SGIA at SGIA.org SGIA Journal ■ Third Quarter 2007 15 Table 2 – Screen Printing Task Completion Time already stretched and coated with These same users also state the technology Task/Consumable Completion Time emulsion. Table 3 lists the direct costs has opened new revenue streams for their associated with screen printing. Note businesses, allowing for additional market Separations 60 Minutes the estimate does not include utilities or share in their regions. Print Film Positives 20 minutes compensate for equipment depreciation. As technology advances, direct-to- (5 min./film) By using screen printing, the net profit of garment inkjet printers will continue to this job would be $306.50, which would be become profitable options for garment Register, Expose and 15 minutes earned in a little more than three hours. decoration. These options are currently Develop Screens Now let’s take a look at how direct- available, but make sure to research all Dry, blockout, dry and 30 minutes to-garment inkjet would hold up: Table 4 the devices that fit your business model. Be tape screens lists the tasks and approximate completion skeptical of print speeds and specifications Setup, print, tear- 60 minutes times to print the same order digitally. As stated by manufacturers. Time the printers, down, reclaim you can see, the order can be completed and determine how long prints really almost two and half hours faster by take. Total estimated time 3 hrs. 5 min. using digital technology. But what about You should also evaluate and determine the costs? Table 5 lists the approximate the speed at which the printer produces a costs associated with producing this job sellable product for your market. Some digitally. perform quite well at 360 dpi while others By using digital technology, the net do not. Determine if adequate coverage is Table 3 – Screen Printing Costs profit of this job would be $334.80, which achieved in one print pass or two. Ask the would be earned in roughly 30 minutes. manufacturers questions about warranties Item Cost So, digital certainly can be a profit center and service level agreements as well as 4 Film positives/ink $4 for the right-sized order. But as order references from customers that bought the quantity rises, screen printing will be a printers. Get their feedback on the level of Screen making consumables more attractive and cost effective choice. satisfaction they have with the device, the (emulsion, tape, blockout, etc.) $3.50 service received and any learning curves Ink per shirt $.25 x 24 $6 Future Technology Developments associated with the hardware or software. Miscellaneous (cleaning chemi- Many direct-to-garment inkjet And be sure to visit SGIA ‘07 (Orlando, cals, platen adhesive, etc.) $4 manufacturers are making improvements Florida; October 24-27, 2007) to see all of to print speed, ink chemistry, overall the latest direct-to-garment printers. Labor @ $12/hr. $36 durability and user friendliness of their machines. Modifications and upgrades Total estimated costs $53.50 are constantly released to address workflow or functionality issues, and include on-board pre-treatment applicators, magnetic stirrers to keep pigment suspended in bulk ink systems Another misconception Table 4 – Direct to Garment Inkjet and evacuation fans to draw dust and lint Task Completion Time away from the print head. Manufacturers is machines can be used only also are incorporating digital devices Task Completion in traditional screen printing presses, when they are Time needed marrying the two technologies into a RIP file 2 minutes single unit. for an order. In reality, Print time of 45 seconds per shirt 18 minutes The next disruptive technology to impact digital inkjet printing will be single direct-to-garment inkjet devices Cure time of 40 seconds per shirt 16 minutes pass devices capable of printing an image Total estimated time 36 minutes in just a few seconds. Using Micro-Electro perform better when Mechanical Systems (MEMS), future print heads will be cheaper to make, have smaller they are continuously ink orifices and feature much larger nozzle arrays to increase resolution and print printing. speed. Print heads traversing back and Table 5 – Direct to Garment Inkjet Costs forth will be replaced by a full-width print Item Cost head array to produce full-color printing at Labor @ $12/hr. $7.20 lightning speeds in a single pass. Direct-to-garment inkjet is definitely Ink per shirt $.75 x 24 $18 here to stay. The installed base of direct- Visit the Digital Apparel Total estimated costs $25.20 to-garment machines is estimated to be approximately 3,500 units worldwide, and Production Zone at SGIA ’07 the adoption rate is expected to continue rising. Many users claim profits generated with their machines enabled them to pay off the device in as little as three months.

16 SGIA Journal ■ Third Quarter 2007 Visit SGIA at SGIA.org