When printing with Direct-to-Film (DTF), it is crucial that your film rolls are round and aligned for continuous printing. Most users, however, experience issues when the DTF film roll is not round. This can cause feeding defects, alignment defects, and printing issues. Several factors can cause this defect, such as improper storage, humidity effects, or manufacturing defects. In this straightforward guide, we will explain the reasons and ways to fix a damaged or bent DTF film roll, ensuring it works well and produces good prints.

Most Common Causes of a Twisted DTF Film Roll

1. Insufficient Storage Conditions

DTF film is susceptible to temperature and humidity changes. If it is poorly stored, it will deform or become oval, and it is tedious to load the film into the printer.

Solution

• Keep your DTF film in a controlled setting, preferably between 65°F - 75°F (18°C - 24°C) with 50% relative humidity.

• Store the rolls upright vertically rather than stacking them horizontally.

• Do not keep film rolls close to heat, direct sunlight, or high humidity.

2. Manufacturing Defects

DTF film rolls may arrive damaged due to insufficient quality checks during manufacturing.

Solution:

• Always inspect new rolls before use.

• Purchase premium DTF film from reputable vendors.

• If a damaged roll is received, call the supplier to have it replaced or refunded.

3. Inadequate Handling While Used

Applying too much pressure when mounting the film onto the printer may bend or deform the roll.

Solution:

• Gently place the film roll onto the spindle of the printer.

• Do not push the roll if it does not fit.

• Ensure the roll is placed straight on the feeding machine to prevent skewing.

4. Exposure to Humidity and Moisture

Excess moisture will enable the film to take up water, swell, and become deformed.

Solution:

• Place silica gel packets in the storage space to dehydrate.

• If the film roll is moist, dry it in a room with a stable temperature for several hours before use.

How to Repair a DTF Film Roll Break

If your DTF film roll is damaged, below are some helpful steps to fix its round shape.

1. Manual Reshaping Method

If the adjustment is minor, you can fix the roll using the following method:

• Place the roll on a flat area.

• Use the round core or tube (like a PVC pipe of the same diameter) and wrap the film around it carefully.

• Secure it with a rubber band or tape and let it rest for 12-24 hours.

• This can assist in restoring the roll's initial roundness.

2. Application of Heat and Pressure

Using warm heat can reshape the roll without harming the film.

Steps:

• Preheat oven to 90°F - 100°F (32°C - 38°C).

• Wind the film roll around a cylindrical object of the appropriate size.

• Place the rolled wrap in the oven for 30 to 60 minutes.

• Remove it and allow it to cool in a dry, secure location.

• Be cautious: Don't overheat the film, which will distort or ruin the adhesive side.

3. Utilizing a Film Roll Holder or Tensioner

A tensioner or roll holder can fix shape issues through constant pressure.

Steps:

• Position the roll onto an adjustable tension film holder.

• Let the roll settle for 24 hours with a bit of pressure.

• Gradually loosen and test it on a printer.

4. Placing the Film onto a New Core

If the center of the roll is damaged, the film can be rewound onto a new, undamaged core to fix the problem.

Steps:

• Gently place the film onto a hard surface.

• Place a new core of the proper size.

• Rewind the movie with a powered or hand-rewinder by even turns.
  

Methods to Prevent Future DTF Film Damage

1. Utilize good quality DTF film.

• Buy from reputable manufacturers to get an even, correctly wound roll.

• Avoid inexpensive movies because they can be of poor quality and mis-wound.

2. Maintain Rolls in Correct Conditions

• Store DTF film rolls in a cool, dry place at all times.

• Use protective packaging such as airtight plastic wrap to exclude moisture.

3. Employ a Film Feeder or Unwinder

• If your printer can handle it, add a film unwinder to prevent excessive tension or misalignment during printing.

4. Regularly check and maintain equipment

• Check your printer's tension settings and film feed rollers frequently to avoid feeding abnormalities.

• Clean rollers and guides to remove dust and dirt that could misalign.

Conclusion

An asymmetrical DTF film roll may lead to critical printing problems, misalignment, improper ink adhesion, and unnecessary materials. By detecting the causes and making the necessary adjustments, you can restore the film's shape and still maintain smooth printing operations. Proper handling, storage, and preventive maintenance will prevent deformation and ensure stable, high-quality prints.

By applying these best practices, DTF printing production personnel can avoid costly delays and enhance efficiency in their production process.