Digital Textile Printing: Powering the Shift to On-demand Fashion

Direct-to-Fabric and Direct-to-Garment printing technologies led the market in 2025, accounting for a 33 per cent share, driven by their versatility, production efficiency, and ability to enable rapid customisation in apparel manufacturing.

The apparel and fashion segment dominated with a 42 per cent share, supported by rising demand for personalised, sustainable, and fast fashion solutions enabled by digital printing. Among fibres, natural fibres held the largest share at 48 per cent, reflecting strong consumer preference for cotton-based textiles across apparel and home furnishing applications.

Blended fabrics, however, emerged as the fastest-growing segment, offering a balance of durability, comfort, and sustainability across both fashion and industrial textile categories. Meanwhile, soft signage and promotional materials recorded the fastest growth among applications, driven by increasing demand for lightweight, reusable display solutions across events, retail, and advertising sectors.

Advancing Technology

Digital textile printing continues to advance rapidly, driven by innovations in printhead technology, ink formulations, and software-driven colour management systems. The primary focus remains on improving print resolution, speed, and substrate compatibility.

Recent developments highlight the scale of progress. Modern inkjet printers such as HPRT’s DA186T Plus, equipped with Kyocera printheads, can achieve speeds of up to 1080 m2/hour, enabling large-scale production while maintaining quality and reducing production cycles. This has made DTP increasingly competitive with traditional methods, even for bulk orders. In inks, Sun Chemical’s reactive inks and Kornit Digital’s NeoPigment Robusto have enabled a 50 per cent reduction in dye washout, significantly minimising effluent. Meanwhile, pigment inks used in D.gen’s Artrix H8 have eliminated the need for pre- and post-treatments, cutting water and energy consumption by 80 per cent.

Single-pass printers from Durst and SPGPrints further support high-volume printing on cotton, silk, and blended fabrics, using less ink and water while delivering vibrant and durable results. At the same time, Epson and Roland-backed DTF and UV DTF technologies are enabling heat-free printing on a wide range of substrates, including non-textiles, thereby expanding applications into signage and accessories with the use of neon fluorescent inks.

Beyond hardware and materials, enhanced reliability and automation are lowering operational barriers and improving scalability. IoT-enabled systems now monitor real-time performance, reducing waste by 50 per cent and supporting more efficient, industrial-scale textile printing.

Direct-to-Garment (DTG)

The global DTG printing market is projected to reach nearly $4 billion by 2030, growing at a CAGR of around 13 per cent from 2025 to 2030. The segment is undergoing a significant transformation, shifting from manual, standalone machines to fully automated and connected production environments.

Modern DTG systems now incorporate automated pre-treatment processes, ensuring consistent, high-quality output without the need for highly skilled operators. The market is increasingly defined by rapid automation, eco-friendly water-based inks, and AI-driven quality control, enabling high-speed, on-demand, and personalised apparel production.

Leading players such as Epson and Kornit Digital have advanced printhead technologies that enhance both production speed and resolution, allowing for more intricate designs and higher volumes. At the same time, sustainable practices, including the use of non-toxic, water-based inks and zero-waste production models, are gaining wider adoption.

AI integration is becoming a key hallmark, supporting real-time quality control and improved fabric versatility. The market is largely driven by the growing demand for on-demand personalisation, particularly among small brands seeking rapid, trend-responsive, and small-batch production that helps minimise overstock and reduce carbon footprint. Additional advancements include integrated ‘wet-on-wet’ printing systems, improved compatibility with blended fabrics, and the rising influence of direct-to-film technology.

Direct-to-Film (DTF)

DTF printing is emerging as a strong challenger to DTG, driven by lower costs and increasing automation. While it offers relatively low investment in equipment, enabling print service providers to remain profitable with competitive pricing, its core limitation remains relatively low productivity. Limited improvements in speed and volume continue to restrict its ability to support large-scale, standalone operations.

In response to market needs, recent DTF machines have expanded in width from the more common 600 mm to 800 mm, allowing more graphics to be nested onto the film roll. Ricoh has taken this further with its 1.3 m wide Pro D1600 DTF solution, combining a wider printer with a matching powder/shaker unit. Polyprint’s FilmJet, developed in Greece, can operate at up to 24 sq m/hr with two passes and features a large powder dispenser with automated regulation, enabling a single morning fill to last throughout the day.

Similarly, Brother’s DTRX printer integrates automated printhead maintenance features, reducing operator dependency. Designed as a complete system with both printer and powder shaker, it operates at up to 19.52 sq m/hr, with a resolution of up to 600 × 1200 dpi and a print width of 800 mm, supported by a 10-inch touchscreen interface.

Conventional DTF processes rely on applying a powder binder over wet ink to adhere graphics to textiles. This step not only slows production but also raises safety concerns related to powder handling. As a result, manufacturers are developing powderless alternatives. Japan’s Matsui is working on a drying unit based on a jettable glue approach, which, while offering a thinner film and improved hand feel, currently delivers wash durability of around 15 to 20 washes. Companies such as Dupont and Brother are also exploring similar innovations, including dry toner-based solutions using transfer paper.

DTF is expected to capture significant market share from screen printing, which requires larger production runs and specialised labour. In addition, DTF offers ease of use with minimal manpower. While currently dominant in apparel, its applications are expanding across home textiles such as curtains and bed sheets, as well as various industrial uses. With ongoing improvements in software, material compatibility, print quality, and hybrid solutions such as Epson’s SureColor SC-F series, DTF is steadily evolving into a more efficient, scalable, and environmentally conscious printing technology aligned with modern production and automation needs.

Roll-to-Roll Printing

Roll-to-roll (R2R) printing is rapidly emerging as a standard advanced electronics method for producing flexible displays, sensors, and thin-film batteries, owing to its ability to enable continuous, high-speed, and precise deposition of functional materials.

The technology has witnessed several innovations, including UV-curing, R2RCLIP, and laser cutting. UV roll-to-roll printing allows instant ink drying, enhancing both production speed and print quality across a range of flexible materials. The R2RCLIP technique enables high-resolution 3D printing of complex geometries, such as shape-specific particles, directly onto flexible substrates. Meanwhile, laser cutting is increasingly replacing traditional die-cutting, offering faster and more flexible layout changes, particularly for creating complex via-holes in electronic applications.

R2R printing also reflects a broader shift towards sustainability, with increased use of eco-friendly inks, conductive polymers, and recyclable materials to meet evolving environmental regulations. At the same time, it is being integrated with Industry 4.0 technologies, including automated monitoring, machine learning, and AI-driven data analytics for real-time quality control. Hybrid fabrication is also gaining traction, combining traditional R2R printing with other processes to develop advanced IoT devices, such as integrating printed sensors with flexible circuits.

The market is driven by demand for lightweight, cost-effective components across automotive, medical, and consumer electronics sectors, with the highest growth expected in the Asia-Pacific (APAC) region. In textile applications, R2R printing supports a wide range of inks, including reactive, dispersion, acid, and pigment inks, making it suitable for diverse fabrics ranging from cotton and silk to synthetic materials.

Dye-sublimation Printing

Dye-sublimation printing is evolving with a strong focus on sustainability, speed, and high-definition personalised production. This shift is reflected in the growing use of eco-friendly, recyclable, and biodegradable transfer papers, along with AI-driven colour management and more efficient industrial printheads.

The market is steadily moving towards greener solutions, with advanced machinery reducing water usage, waste, and energy consumption. Modern industrial printers can now achieve one-pass speeds of up to 1,100 m2 per hour, while AI is increasingly used to automate colour management, pattern recognition, and overall workflow efficiency.

At the same time, substrate versatility is expanding, with advancements enabling printing on specialised materials for home décor, signage, and photography. According to a Smithers report, this market is projected to reach €14 ($16.29) billion by 2029, growing at a CAGR of 6.6 per cent, driven by rising demand for customised textiles across fashion and home décor segments.

Bio-based HT System

Bio-based High Temperature (HT) systems, particularly bio-based pigment printing technologies, are increasingly being developed and adopted in digital textile printing to enhance sustainability. These systems significantly reduce water, chemical, and energy consumption compared to conventional screen printing methods.

A notable example is Sri Lanka-based garment printing solutions company Screenline, which has developed printing systems using algae-based pigments derived from renewable biomass instead of petrochemical sources. The company also utilises tea-based pigments created from processed Sri Lankan tea waste. By combining these innovations, Screenline has reduced dependence on conventional chemicals while aligning with the growing demand for low-impact garment decoration. Its sustainability catalogue documents these solutions in detail, highlighting their readiness for commercial adoption.

Screenline’s approach demonstrates how printers can integrate lower-impact chemistry into their operations. In addition, the company has developed systems capable of converting most traditional screen-printing effects into Heat Transfers, improving repeatability tolerances, reducing chemical exposure, and enabling faster turnaround times. This model supports businesses in meeting the increasing global demand for detailed, lightweight, and high-performance garment graphics.

Sustainability Driving the Shift to DTP

The digital textile printing (DTP) industry is responding more actively than ever to rising consumer awareness around sustainability. The market continues to expand, driven by environmentally conscious consumers who are pushing brands to adopt digital textile printing and rely increasingly on software programmes across multiple applications.

Brands are shifting towards designs created using textile design software and produced through inkjet printing technologies that avoid harmful dyes, instead using heat transfer or powder dyes while consuming significantly less water than traditional methods. At the same time, digital textile printing facilities, which require less space and fewer resources compared to conventional printing and dyeing setups, are gaining wider adoption among companies.

Print companies are also transitioning towards lower-energy printing solutions, recyclable substrates, and eco-friendly ink formulations to meet procurement standards and regulatory requirements. Environmental regulations and corporate sustainability commitments have further accelerated the shift from conventional printing methods to digital alternatives.

Key advantages such as reduced water consumption, lower chemical waste, and decreased energy usage are making DTP increasingly attractive for organisations focused on ESG compliance and operational efficiency. Strategically, this sustainability-driven transition is influencing capital expenditure decisions and reshaping competitive positioning, particularly for manufacturers targeting environmentally conscious markets.

Circularity Across the DTP Value Chain

A range of circular opportunities is emerging across the DTP supply chain, spanning digitalisation and process optimisation, sustainable sourcing and consumables, hardware life extension, end-of-life management, and data-driven transparency. Companies are increasingly using recycled and FSC-certified or alternative fibres such as bamboo or sugarcane paper to reduce reliance on virgin resources. At the same time, circular or high-yield toner and ink cartridges are being adopted to minimise replacement frequency, while eco-solvent and bio-based inks are supporting the shift towards biodegradability.

As part of reuse and repair initiatives, companies are turning to third-party refurbishment services to extend the life of printers and scanners rather than replacing them. Equipment designed for easy disassembly and repair, allowing component-level upgrades instead of full unit replacement, is becoming a priority. Leasing printers instead of purchasing new ones is also gaining traction as a circular strategy.

Partnership programmes are being implemented to ensure vendors collect used paper, toner cartridges, and end-of-life hardware for recycling into new products. E-waste harvesting, which involves extracting rare materials and components from old equipment for reuse, is helping reduce dependence on raw material extraction. Repurposing is also becoming more common, with companies converting unavoidable waste into new materials such as packaging fillers or composite products.

In line with Digital Product Passport (DPP) requirements, companies are using technology to track the composition of materials and components across the supply chain, enabling effective recycling and reuse at end of life. Additionally, AI-optimised reverse logistics systems are facilitating the return of used printers and cartridges to authorised recycling centres, helping to minimise transportation-related emissions.

Lowering Entry Barriers for New DTP Players

Not all print companies currently operate in textile printing, but for those looking to enter the segment, garment printing offers an accessible starting point. Beyond apparel, opportunities are expanding across promotional wear, home textiles, soft signage, and interior applications. Recognising this shift, manufacturers are introducing entry-level solutions to support new entrants in their transition.

Epson has introduced the SureColor G6000, the first DTF and R2R printer, designed to suit both newcomers and experienced users. In the R2R segment, Roland’s VersaSTUDIO BN2 Series provides an ideal platform for start-ups, creators, and small print businesses aiming to bring production in-house.

For promotional wear, Mimaki’s TxF Series DTF printers offer flexibility and ease of use, making them suitable for short runs and customised jobs. Meanwhile, Mimaki’s TS200-1600, featuring an extended eight-colour configuration including orange, violet, and newly developed fluorescent pink and yellow inks, is well suited for dye-sublimation, enabling the creation of vibrant, eye-catching applications.

For users seeking broader fabric compatibility, including natural fibres, Mimaki’s TRAPIS solution provides an accessible entry point. Using a transfer-based process similar to dye-sublimation but with textile pigment inks, it allows printing on materials beyond polyester, making it suitable for applications such as cotton-based textiles and interior décor.

Additionally, with a print width of up to 1,940 mm, Mimaki has expanded its TS330 Series to TS330-1800, enabling users to target higher-value applications such as curtains, tapestries, and large-format soft signage for interior and commercial spaces.

AI-Driven Transformation in DTP

Artificial intelligence (AI) is rapidly transforming textile printing, extending far beyond its early use in optical inspection systems for defect detection. Today, AI is embedded across the entire printing value chain, from predictive maintenance and component replacement to robotic automation for substrate handling and precision tasks, as well as design creation and proofing.

Zimmer Austria provides a strong example of AI in action. Its AI-powered systems continuously monitor machine performance to predict maintenance needs, minimising downtime and reducing costs. Real-time diagnostics enable instant detection and correction of printing irregularities, ensuring consistent output quality. Predictive analytics further optimise operational parameters, extending equipment life and improving overall productivity. Additionally, advanced camera detection systems allow precise alignment of designs, addressing challenges such as weft misalignment and fabric shrinkage.

Zimmer’s AI integration also enables the creation of customised textile designs aligned with consumer preferences and market trends. By streamlining the design process, AI reduces lead times, enhances adaptability, and supports rapid responses to changing fashion and interior demands. The company has also applied AI in camouflage textile production, using environmental and infrared data to generate optimised patterns, significantly improving concealment effectiveness and tactical performance for defence and military applications.

In China, AI-powered imaging systems have enabled real-time fabric colour calibration, increasing digital printing pass rates from around 50 per cent to over 90 per cent by addressing long-standing production bottlenecks. Meanwhile, AI-driven design and automation solutions such as Kornit Digital’s Presto are further streamlining workflows, predicting errors, and optimising ink usage.

Hybrid Printing: Blending Precision with Production Efficiency

Hybrid printing, which combines traditional screen printing with inkjet technology and digital workflows, is gaining traction among brands seeking a balance between detail, durability, and shorter development timelines. The approach leverages the strengths of both methods, with screen printing suited for base coats and high-volume, low-cost solid colours, while digital printing enables complex, high-definition, and personalised graphics. As a result, many specialised printers are increasingly operating both technologies side by side within their production facilities.

In March, Mimaki introduced the hybrid UV inkjet UJ330H-160 as part of its new 330 series of large-format graphic printers. This system enables both roll and rigid output within a single unit, addressing space constraints and reducing capital investment requirements. Equipped with a high-density, high-definition print head and proprietary image quality control technology, the printer supports direct printing on rigid materials alongside roll-based applications.

Designed for quick and seamless switching between roll and rigid output, the UJ330H-160 enhances production efficiency while offering flexibility across a wide range of materials and applications. It can operate effectively even with limited personnel and space, eliminating the need for multiple machines. The integration of RasterLink7 RIP software further ensures consistent control and high-quality output for value-added printing applications.

Future Outlook: Towards a Digital, On-Demand Textile Ecosystem

The textile industry is moving decisively towards a future that is increasingly digital, on-demand, and sustainable, driven by technologies that are already reshaping production processes. Businesses that embrace innovation stand to benefit significantly, while those that fail to adapt to emerging trends risk falling behind.

Printing companies must navigate a rapidly evolving digital landscape, where success will depend on more than just print quality. Agility, operational efficiency, sustainability, and the ability to deliver personalised products at scale are becoming critical differentiators.

As this transformation accelerates, traditional methods that are water-intensive and wasteful are expected to be replaced by a more advanced and efficient digital ecosystem operating at scale.