DTF White Ink Not Printing Properly? How to Troubleshoot Weak White Layers and Head 1 Disconnection Issues

Question:

I saw BCH Technologies recommended on a Procolored Facebook group and decided to reach out. I've been troubleshooting my DTF printer independently since the manufacturer's tech support hasn't helped. I replaced both printheads, cleaned the ink pump, flushed and replaced the white ink with a better brand, and my nozzle checks look perfect. Despite that, my prints are coming out with barely any white underbase, which leads to cracking when heat-pressed. Print EXP also says that Head 1 (which is the white) is disconnected. I attached a photo showing the weak white layer—what might be causing this, and how can I fix it?

Answer:

🖨️ Understanding the Weak White Ink Issue in DTF Printing

From what you've described, you’ve done a lot of the right things—replacing printheads, cleaning the ink pump, and flushing/replacing white ink are essential steps. And your nozzle check showing perfect results indicates that the mechanical components of the printer are functioning well.

Let’s break down what may be happening and what could be causing the white ink to appear weak or disconnected.

🧩 Possible Causes and Fixes:

1. Head 1 Disconnected in Print EXP

If Print EXP is showing that Head 1 is disconnected, that’s a serious flag. Head 1 is typically the channel assigned to white ink in most DTF setups. If the system believes the printhead is disconnected, even momentarily, it may stop sending white ink data to the printer. That results in faint or missing underbase—even if the printhead is technically firing.

What to check:

• Cable Connection: Reseat the FFC (flat flexible cables) connecting Head 1 to the mainboard. Inspect for any burn marks, kinks, or loose connections.

• Printhead Detection: Some printers require re-initialization after replacing heads. Make sure the head is recognized by both the firmware and Print EXP.

• Mainboard or Carriage Board Fault: If all else looks good, one of these boards may be partially failing, especially if only white ink (Head 1) is affected.

2. Ink Flow or Air Bubbles in White Channel

Even with a good nozzle check, intermittent white ink flow can occur due to:

• Microbubbles in the white ink line.

• Ink starvation caused by a partially clogged damper or faulty ink pump pressure regulation.

Try this:

• Do a head soak using DTF-safe cleaner (not distilled water) on a lint-free pad for 30–60 minutes.

• Check your white ink dampers and hoses to ensure there’s no backflow or trapped air.

3. Low Ink Density or Diluted Ink

From the photo you shared, the white is laying down a very thin layer. While the curing looks excellent (no overbake or charring), the opacity of the white layer looks too weak to bond with adhesive powder properly—leading to cracking when pressed.

Potential fix:

• Try a different DTF white ink brand that’s known for higher opacity and heavier pigment load.

• Increase the white ink density or pass count in your RIP software (Print EXP or similar).

• Adjust the white underbase pixel coverage—sometimes shrinking the white layer slightly helps keep it under the color layer and boosts density.

4. Software or Print Mode Misconfiguration

Even if your hardware is working, the issue could lie in the software configuration. Check:

• That the print mode or profile is correct for your media and ink type.

• Whether white ink layers are enabled and set to the right pass count.

• If using custom ICC profiles or drivers, confirm that they are correctly mapped to the channels.

⚠️ Cracking After Heat Pressing

Cracking is often caused by:

• Insufficient white underbase (as we discussed).

• Overstretching or rough handling of the pressed garment.

• Pressing garments that are not fully cured or using incorrect temperature/time/pressure settings.

If your white ink layer is too thin, it won’t fully bind to the powder adhesive, making it brittle after pressing. That’s likely what you're seeing.

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. So, we're not able to provide remote troubleshooting, suggestions, or support for printer repairs. We offer an in-person evaluation and repair service [https://bchtechnologies.com/printer-repair-service] through our local diagnostic facility. Due to high demand, this service is first-come, first-served, and may require several weeks before drop-off is available. Our service options include full printer repairs or focused part replacements, but we understand our rates might not be the lowest. Therefore, we strongly encourage exploring DIY solutions through research. Start with our YouTube channel [https://youtube.com/@bchtechnologies] and use the search icon under the "About" section to locate videos on related topics. We’ve created videos for nearly a decade, and while we may not recall every one off the top of our heads, YouTube’s search function often surfaces exactly what you need—including helpful videos from other creators.

Thank you again for reaching out to BCH Technologies. We truly hope you find a solution soon and get back to creating high-quality DTF prints. If you need any tools, parts, or cleaner recommendations, we’re always here to help.