From Garage to Growth: How "InkThread Apparel" Scaled Custom T-Shirt & Hoodie Production with Automated DTF Printing Technology
Client:
InkThread Apparel, a fast-growing online custom apparel company in Austin, Texas, USA, catering to small businesses, schools, sports teams, and direct-to-consumer graphic tee sales.
Company:
Urban Fabricate Studio
Location:
Berlin, Germany
MTUTech Printer Model:
MT-UV 2513GX Industrial Flatbed UV Printer
Challenge:
Starting with heat transfer vinyl (HTV) and later direct-to-garment (DTG) printing, InkThread faced significant bottlenecks as order volumes grew. HTV was labor-intensive for multi-color designs, and DTG, while good for cotton, was slow, required extensive pre-treatment, and performed inconsistently on popular 50/50 blends and polyester-rich hoodies. They struggled with production speed, high labor costs per shirt, and the inability to reliably produce vibrant, full-color designs on dark garments and a wide range of fabrics without compromising softness or durability.
Solution:
InkThread integrated MTuTech all-in-one DTF system into their production line. This complete system included a dedicated DTF printer, and a dual station heat press.
Implementation & Process Details:
InkThread integrated MTuTech all-in-one DTF system into their production line. This complete system included a dedicated DTF printer, and a dual station heat press.
Design & Printing
Designs are printed in mirror image using a specialized DTF printer with CMYK + White ink onto a clear, carrier PET film. The white ink layer is printed first, creating a vibrant underbase for colors on dark garments like black hoodies.
Powder Application & Curing
The printed, wet film immediately passes through an automatic powder shaker that evenly coats the entire image with a fine, hot-melt adhesive powder. The excess powder is vacuumed away. The film then enters a curing oven where low heat melts the powder, embedding it into the ink layer.
Heat Transfer Process
An operator places a garment (100% cotton tee, 50/50 sweatshirt, or even nylon jacket) on the heat press. The cured DTF film is cut to size, placed ink-side down on the fabric, and pressed at a specific temperature and time (e.g., 160°C for 15 seconds). No pre-treatment of the garment is needed.
The “Peel” & Finish
After a brief cool-down, the PET film is peeled away, leaving a soft, flexible, and highly durable print that is embedded into the fabric fibers. The finished feel is superior to traditional vinyl, with excellent stretch and wash resistance.
Results & Benefits:
Fabric Versatility & Quality
Successfully printed the same vibrant, full-color design across their entire product line—from 100% cotton tees to polyester sports jerseys and heavyweight cotton-poly hoodies—with consistent, reliable results and a soft hand feel.
Dramatic Increase in Production Speed
The DTF process, especially with automation, allowed them to print hundreds of unique designs per day in advance, then rapidly heat-press them as orders came in. Throughput increased by over 300% compared to their previous DTG setup.
Reduced Operational Complexity
Eliminated the need for garment pre-treatment, platens, and frequent printhead maintenance associated with DTG. This lowered skill barriers for operators and reduced consumable costs.
Enhanced Durability & Customer Satisfaction
Prints demonstrated excellent wash fastness, withstanding 50+ home launderings without cracking or fading, leading to a significant drop in customer complaints and returns.
Quote from Client:
*MTuTech 60cm DTF system was the scalability key we were missing. We finally have a one-stop solution for 90% of our orders. The automation lets one operator manage what used to take three. Our best-selling product is now full-color, all-over prints on black hoodies—something that was a constant headache with DTG. The consistency and speed have allowed us to confidently take on larger corporate orders and scale our direct-to-consumer business beyond what we ever imagined.”*
– Marcus Rivera, Founder & CEO, InkThread Apparel