Fabric printing methods: digital, rotary, reactive and pigment
Two questions describe a printed fabric: which machine put the design on, and which colourant was used. The first affects run length and design; the second affects hand feel and colour fastness.
Printing methods
| Method | How it works | Typical use |
|---|---|---|
| Rotary screen | One cylindrical screen per colour | Long runs with a limited number of colours |
| Flat screen | Flat screens print one after another | Designs with a large repeat |
| Digital | Inkjet printing, no screens | Short runs, multi-colour and photographic designs |
Rotary printing and pattern repeat
The repeat is the length after which the design repeats along the fabric. In rotary printing it depends on the screen circumference. The standard repeat is 64 cm; some machines print 91.4 cm or 101.8 cm. Each colour needs its own screen, so there is a set-up cost that spreads out over long runs.
Digital printing
No screens are needed. There is no limit on colours, and smooth gradients print cleanly. Designs are easy to change, which makes digital the usual choice for short runs and sampling. There is no repeat limit either, so a single panel can cover a whole duvet cover. Output per metre is slower than rotary.
What 3D and 5D print means
In home textiles, 3D or 5D print is a sales name for digitally printed designs with a depth or shadow effect. The fabric surface is flat and the effect is purely visual. Ask separately about the print method and colourant.
Reactive and pigment printing
- Reactive dyes form a chemical bond with cellulose fibres such as cotton and viscose. The fabric stays soft and wash fastness is usually good. Printing is followed by steaming and washing off.
- Pigments sit on the fibre surface, held by a binder. No steaming or washing off is needed, so the process is shorter. Deep shades can stiffen the hand, and rub fastness can be lower than with reactive printing.
- Polyester is printed with disperse dyes, which includes sublimation printing.
Colour fastness
Colour fastness is how well a colour stands up to washing, rubbing and light. Common tests are ISO 105-C06 for washing, ISO 105-X12 for dry and wet rubbing and ISO 105-B02 for light. Wash and rub results are graded 1–5 on the grey scale; light fastness is graded 1–8 on the blue scale. For hotels and items washed often, ask for test reports with the quote.
In the TkanIstanbul catalog, printed fabrics have their own subcategories under each fabric type, such as digital print poplin, printed flannel and digital print muslin. Specifications for each series are on its series page.