Why Is My DTF Film Showing Flakes? How to Diagnose and Fix Powder Adhesion Issues

Customer Question:
I'm seeing flakes on my DTF (Direct-to-Film) transfer film after printing. What could be causing this issue, and how can I fix it?

Answer:

Understanding Flakes on DTF Film

If you're noticing flakes on your DTF transfer film, this typically indicates a problem with the adhesion process between the powder and ink, and in some cases, moisture contamination. Let's break it down by potential causes and how to address them:

1. Poor Adhesion Between Ink and Powder

This is one of the most common culprits for flaking issues.

• Ink Not Wet Enough at Powdering Stage: If the ink begins to dry before the powder is applied, the powder won’t stick properly. Make sure you're applying powder right after printing—don’t let the film sit too long.

• Powder Application: Ensure that the adhesive powder is applied evenly and thoroughly. Shake off excess, but make sure the wet ink is fully coated before curing.

• Powder Quality: Over time, DTF adhesive powder can absorb moisture or degrade, especially if stored improperly. If your powder is clumpy, sticky, or inconsistent in texture, replace it with fresh powder.

2. Incorrect Curing Parameters

Curing (or baking) is critical to ensure the powder melts into the ink and binds properly.

• Undercuring: If your curing temperature is too low or the time too short, the powder won’t melt fully, leaving loose particles that appear as flakes.

• Overcuring: On the flip side, too high a temperature or excessive curing time can cause the film to become brittle and more prone to flaking during handling or transfer.

  Suggested Curing Ranges:

  • Temperature: ~320°F (160°C)

  • Time: 2–3 minutes, depending on your oven or heat press

  • Always use an IR thermometer or temperature gun to verify the actual surface temperature.

3. Environmental Moisture

Humidity plays a role—especially if:

• Your film or powder has absorbed moisture before use

• Your work area isn’t climate-controlled

Drying your film slightly (but carefully!) before powdering or curing in a low-humidity environment can make a significant difference.

Additional Tips:

• Store your powder in an airtight container with desiccants.

• Keep your film in its original sealed packaging until use.

• Run a controlled test strip before starting a full print batch to avoid waste.

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 via our local diagnostic facility (https://bchtechnologies.com/printer-repair-service). Given the high demand, we operate on a first-come, first-served basis. So, it might take a few weeks before we can get your printer to drop it off. Our services are structured to repair either a whole printer or specific parts, with clear instructions on how to proceed. However, we acknowledge that our rates aren't the most economical. Thus, we highly recommend that you resort to self-help via online research. You can start by checking out YouTube or visiting our YouTube channel's homepage (https://youtube.com/@bchtechnologies). Look for specific videos using the search icon next to "About" on the right-hand side of the menu bar. I receive dozens of queries every day asking about videos for specific topics. Having created videos over the past nine years, it's challenging to remember every single one. Therefore, using YouTube's search function would be most efficient. Plus, YouTube might suggest relevant videos from other channels that could assist you.

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