Epson XP-15000 DTF Conversion: Star Wheels, Film Feeding, and Print Space Questions Answered

Question:
When performing a 6-step Epson XP-15000 DTF conversion (relocating the CSIC, waterproofing the printhead, and removing the star wheels), why do people remove the star wheels? Since the film passes on the non-print side, does it really matter? Also, can using roll feeding help prevent the loss of about two inches of print space?

Answer:

Why Remove the Star Wheels?

The primary reason people remove the star wheels (also known as pizza wheels) during a DTF conversion is that they tend to scratch or dent the surface of the PET film. Even though the ink is printed on one side, the pressure from the wheels can leave marks or impressions on the non-printed side. These scratches may not always be visible immediately, but they can affect ink adhesion, powder curing, and the overall smoothness of the print.

In some printers and under certain conditions, star wheels are not a significant issue, but with the Epson XP-15000 and similar models, the risk of scarring the film is high. This is why many users opt to remove them during the conversion process. For a more detailed visual explanation, you can check out this video: Why Remove Star Wheels in DTF Conversion (https://www.youtube.com/watch?v=-mHXXV2tP1o).

Does the Film Passing on the Non-Print Side Make a Difference?

While it’s true that the star wheels contact the non-print side of the film, the issue isn’t with ink transfer but with mechanical scarring. Since DTF film needs to remain as smooth as possible for powder application and curing, even subtle marks can cause uneven powder melting or adhesion problems. That’s why many users still recommend removal, despite the wheels only touching the back side of the film.

Can Roll Feeding Prevent the Loss of 2 Inches of Print Space?

Yes, roll feeding can help optimize print space, but it’s not a perfect solution. Desktop printers, such as the Epson XP-15000, typically have built-in margins and feeding mechanisms that cause a loss of around 1.5–2 inches at the start and sometimes at the end of the print. Roll feeding enables continuous printing, which reduces wasted space at the beginning of each job; however, some margin limitations will still be imposed by the printer firmware.

Some users find success with third-party roll adapters or modified feeding paths, but keep in mind that the XP-15000 was not initially designed for rolls. Proper alignment and tension control are essential to prevent skewing or jams when using roll setups.

Addressing printer issues can be complicated since many of these challenges require hands-on adjustments. Due to this, we are unable to provide remote troubleshooting, suggestions, or repair support. However, we do offer an in-person evaluation and repair service through our local diagnostic facility (https://bchtechnologies.com/printer-repair-service). Our process operates on a first-come, first-served basis, and depending on demand, it may take a few weeks for us to receive your printer for inspection. We can service entire printers or specific components, with clear instructions on how to proceed. That said, we recognize our rates may not be the most economical, so we strongly recommend self-help through online resources. A good starting point is our YouTube channel (https://youtube.com/@bchtechnologies). Use the search icon on the channel’s page to find videos covering your specific topic quickly. With more than nine years of uploads, it’s difficult to recall every single video by memory, so YouTube’s search feature is the most efficient way to find guidance. Plus, it may recommend helpful videos from other creators as well.

Thank you again for your thoughtful question and your engagement with BCH Technologies. We genuinely appreciate your support and wish you success with your XP-15000 DTF conversion journey.