BY2-20 Usage Guide

This guide explains topics that you need to understand when using the BY2-20 DTF (Direct to Film) printer to create products.

It contains the flow to follow to create products as well as precautions for each process (such as media management, maintenance, and environmental conditions). Use this guide to create products with stable quality.

Characteristics of DTF Ink

To enable stable output of ink for DTF, it is important for you to manage the temperature and humidity as well as to perform daily maintenance.

Managing the temperature and humidity of the environment where the machine is installed
icon_thermometer icon_water-drops
Temperature: 20°C to 28°C (68°F to 82.4°F) Humidity: 40 to 60% RH (with no condensation)

We recommend that you manage the temperature and humidity under the same conditions even when the machine is not operating. If it is difficult to do so, use air conditioning to adjust the temperature and humidity to the ambient temperature and humidity before starting printing. Then, wait for the internal temperature and humidity of the machine to match the ambient temperature and humidity before using the machine.

Warnings and operations under high temperatures
Warning Internal temperature of the machine Operation
High-temperature alert 28°C (82.4°F)

Warning

It is possible to continue printing, but doing so may impair the performance of the machine.
High Temperature Error (Printing Stopped) 35℃ (95 °F)

Printing stops.

It is no longer possible to set up the media.
High Temperature Error (Operation Stopped) 40°C (104°F)

Operation stops.

All operations, including ones such as cleaning, are stopped.
Managing film and powder

If film and powder absorb moisture, their performance deteriorates.

  • Film: After printing, remove the film from the machine, insert the film into a vinyl bag with desiccant (silica gel), and then store the film.
    BY2_Film
  • Powder: After use, store the powder in a hermetically sealed container. It is effective to include desiccant (silica gel) in the container.
    BY2_Powder
Daily maintenance
To maintain product quality and stable machine operation, be sure to perform the following operations.

Procedure for Creating Products

A video showing the flow of operations is available. In addition to reading this section, also view this video.

BY2-20 Workflow

Step 1 Creating print data
  • Create a white plate *1 on top of the CMYK.

Step1.2_Print.
Step 2 Printing on the film
  • Print CMYK followed by Wh.
  • Print the image mirrored *2 on the film.

Before the ink dries, proceed to the powder application step.

Step 3 Applying powder
  • Apply powder to the ink before it dries.
  • The powder will become the adhesive that attaches the ink to the material.

Remove excess powder and proceed to the next step.

Step3_Powder
Step 4 Dissolving the powder
  • Dissolve the powder at the appropriate temperature and for the appropriate time to change the powder to glue.
    • Dissolving temperature: 150°C to 160°C (302°F to 320°F)
    • Dissolving time: 180 to 300 seconds
  • Use an oven or shaker that has a smoke discharging function or a smoke absorber.
  • If you will not transfer the film immediately, store it in a manner that prevents it from absorbing moisture.

Cool the film, and then proceed to the next step.

Step4_Bake
Step 5 Transferring the film with heat and pressure
  • Using the appropriate temperature and pressure *3 , transfer the film to a T-shirt or a similar material.
  • We recommend that you use an iron press machine.
    • Temperature: 150°C to 160°C (302°F to 320°F)
    • Transferring pressure: 300 kg (661.4 lb.)
  1. Preheating press

    Purpose: To remove moisture and wrinkles from the material and to preheat it

    Result: Flattening the material and removing moisture from it makes it easy to affix the printed object to the material.

  2. Main press

    Purpose: To transfer the printed object to the material and affix it there

    Result: The DTF sheet adhesive is dissolved under the set conditions of temperature, pressure, and time, firmly affixing the adhesive to the fibers of the material.

    After pressing, wait for the film to cool down fully before peeling it off.

  3. Finishing press

    Purpose: To improve the durability and adjust the texture

    Result: The print surface is more firmly blended together with the fibers.

    After peeling off the film, apply a dual-sided, silicone-processed sheet to the material and press it again.

Step5_Press
*1 You can create white plates in VersaWorks.
*2 In VersaWorks, the print data is automatically mirrored.
*3 The temperature and time vary depending on the film and powder you are using.
IMPORTANT

The conditions for dissolving the powder and for pressing assume that you are using genuine film (S-F164) and genuine powder (S-POWDER).

The optimal conditions vary greatly depending on the materials you are using.

Examples of Main Problems

Oil sitting on top of the transferred surface
This is a phenomenon where oil sits on top of the print surface after transferring to a T-shirt or something similar with an iron press machine. It is especially noticeable in black, navy blue, and similar locations where the ink density is high. This phenomenon does not just occur immediately after the transfer. Oil may also come out from the print surface approximately one day after the transfer.
BY2_oil
  • Cause

    Moisture remains due to incorrect settings during the powder dissolving process.

  • Action

    Process at the appropriate temperature and for the appropriate length of time. You may also be able to improve the symptoms of this problem by discharging the smoke.

IMPORTANT We strongly recommend that you use an oven or shaker that has a smoke discharging function or a smoke absorber.
Moisture runs or drips from the circumference of the printed object
This phenomenon occurs when the film is not handled and the machine is not operated in an appropriate environment. If you proceed to the next step as is, powder will attach to the moisture, leading to glue remaining on the material and resulting in a defective product.
BY2_water
  • Cause

    The film has absorbed moisture, or the humidity in the printing environment is too high. Alternatively, after printing and the application of powder, the film was left without dissolving the powder.

  • Action

    Store and handle the film and store and operate the machine in appropriate environments. Furthermore, perform the printing, powder application, and powder dissolving steps in sequence without waiting between them.

The colors are not clear and the white ink drips with non-genuine film
If you use commercially available film, the white ink will drip and less vibrant colors will be printed. Of special note, black (K100) may be printed as gray.
BY2_3rdDGFilm
  • Cause

    Likely causes are the drying capability of the film and its compatibility with the machine as well as variations in the film quality when it is manufactured.

  • Action
    Try to make the following adjustments and settings.
    • Adjust the temperature of the heater and the dryer.
    • Print Quality: High Quality
    • Direction: Uni-Direction

    If drying is still difficult even after you make these changes, use genuine film (S-F164) made by Roland DG.

Nozzle drop-out cannot be corrected
Even if nozzle drop-out does not appear to be improved by cleaning, there may be no effect on products if drop-out occurs in just a few locations. Try printing. If you can judge that the product is not affected, use the printer without any further cleaning.
  • Guideline for what is acceptable: Dot drop-out is not concentrated in one area.

    BY2-20_SPG2_TestPatternOK

  • Guideline for what is not acceptable: Dot drop-out is concentrated in one area.

    BY2-20_SPG2_TestPatternNG

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