HONGSAM Delivers a Safe and Efficient Powder-free DTF Printing Solution for Mass Production

Traditional DTF processes rely on fine TPU particles as hot melt powder. The powder-shaking stage generates floating dust, while those tiny particles can penetrate deep into the lungs. Long-term inhalation poses serious risks to operators’ respiratory systems. HONGSAM powderless DTF printing solution completely eliminates both the hot melt powder and the powder-shaking process, removing dust pollution at its source. The production environment stays clean and safe, better meeting workplace safety standards and global environmental regulations, while protecting the health of frontline workers.

Conventional DTF white-ink heat-transfer printing has long depended on the hot melt powder shaking. Heavy dust and health hazards in the work environment have become major obstacles to safer and greener industry development. As powder-free DTF printing technology moves into industrial-scale production, HONGSAM has introduced a mature, complete powder-free DTF ink system. With multiple core advantages, it offers domestic and international printing factories as well as small studios a stable, mass-producible powder-free printing path.

Between 2006 and 2017, HONGSAM spent more than a decade tackling the fundamental challenges of pigment ink formulation and the chemical reactions of digital textile printing. The company steadily solved industry problems such as fabric adhesion, color stability, and wash fastness, gradually building a complete ink R&D system. At the 2015 Shanghai International Digital Printing Industry Exhibition, HONGSAM first public demonstrated its next-generation Jetextile^® textile pigment ink direct-to-fabric process—already planting the technical seeds for green, dust-free printing.

During the Shanghai ITMA International Textile Exhibition held from 15 to 19 October 2018, HONGSAM’s RCT ™ process—requiring no pre- or post-treatment—made its debut. Based on digitally-controlled chemical reactions, it overturned the traditional reliance on chemical auxiliaries and high-temperature processing, clearing key technical barriers for powder-free DTF technology.

In 2020, conventional DTF powder-shaking heat-transfer technology spread rapidly across the China market. The fast, flexible customization model fueled explosive growth in personalized apparel printing, yet problems such as dust pollution, wasted hot-melt adhesive powder, powder overflow at pattern edges, and reduced garment breathability became increasingly obvious. The market urgently needed a simpler, cleaner, higher-quality alternative. HONGSAM quickly identified these pain points. Drawing on years of RCT technology experience, the company launched a dedicated R&D program for powder-free DTF printing solution. In 2021 it established the Hong-Jet Business Unit specifically to integrate, industrialize, and promote the Hong-Jet series of digital printing solutions, beginning a thorough redesign of traditional DTF processes.

At the Guangzhou International Textile Printing Industry Exhibition held from 18 to 20 August 2022, HONGSAM’s full digital offset heat-transfer solution—Hong-Jet^® powder-free DTF printer—was officially unveiled to the national industry for the first time. This marked the first close view of a pure digital, industrial-scale powder-free DTF solution in China’s digital printing sector. On site, HONGSAM set up a dedicated demonstration station that fully showcased the streamlined three-step process of “print – dry – heat press.” Compared with the dusty chaos of traditional powder-shaking equipment, the demonstration clearly highlighted dust-free production, precise patterns without powder overflow, and a soft hand feel. Large numbers of printing processors and distributors stopped to watch, making it one of the most disruptive technical highlights of that year’s exhibition.

In 2024, HONGSAM presented the further upgraded Hong-Jet^® powderless DTF solution at the TSCI International Digital Printing Industry Application Exhibition and the Shanghai International Textile Machinery Exhibition. Equipment stability and ink film-forming performance were improved, and the reproduction of gradient patterns and fine text was refined, further strengthening the technology’s advantages.

From 4 to 7 March 2025, at the Shanghai International Advertising Printing Exhibition (APPPEXPO), HONGSAM displayed Hong-Jet^® full digital offset heat-transfer equipment together with finished prints on a wide range of fabrics.

In October of the same year, HONGSAM went overseas and exhibited at PRINTING United in the United States. The Hong-Jet^® “No Powder DTF” branding was highly visible. On-site displays of apparel, bags, and home-textile prints, together with the soft, breathable fabric hand feel and the clean, dust-free production logic, challenged overseas perceptions of Chinese DTF technology. Many international buyers stopped to discuss business, marking the start of the Hong-Jet solution’s global rollout.

In 2026, HONGSAM accelerated its exhibition schedule: Guangzhou ITCPE Textile Printing Exhibition, Shanghai International Advertising Printing Exhibition, Mexico’s EXINTEX Textile Industry Exhibition, and Hangzhou TSCI Digital Printing Exhibition followed one after another. At every show the latest powder-free DTF machine was presented, evolving from split-type machines to integrated intelligent systems. Continuous optimization of ink film-forming performance further improved the stability and versatility of the powder-free DTF printing technology, establishing it as a benchmark solution in the green DTF segment at both domestic and international exhibitions.

Hong-Jet^® has already completed end-customer validation and achieved stable industrial production. The complete CMYK + white ink + adhesive ink system has been proven in large-scale manufacturing. Print quality meets standard wash-fastness requirements for the apparel industry, and is suitable for cotton, blends, synthetic fibers, and other mainstream fabrics. Finished prints feel soft and smooth, free from the heavy, rubbery hand feel caused by traditional hot-melt powder. Wearers would not experience the gel-like discomfort, which significantly improving the end-garment wearing experience.

Some powder-free DTF solutions currently on the market rely on equipment modifications to improve wash fastness. After such hardware changes, printheads remain under prolonged high-temperature radiation, which directly affects continuous production capability. HONGSAM powder-free DTF ink solution follows a path of fundamental ink-formulation optimization. No carriage modifications to existing printers are required, and no infrared heating lamps needed. Printheads operate at normal temperature throughout, avoiding continuous high-temp damage and ensuring long, uninterrupted production runs.

A matching print-and-dry all-in-one machine is also available. The complete unit occupies only 2 square meters. Its compact, integrated design facilitates container shipping overseas and is well suited to overseas customers, urban studios, and small-batch customization shops. A complete powder-free DTF printing line can be set up in a small space without the need for large factory floors. HONGSAM powder-free DTF printing solution is designed for real production conditions and serves both high-volume factory processing and small-order overseas studio customization. The entire process is completed in three steps—print, dry, and heat transfer—simplifying production and reducing manual intervention.

Hong-Jet^® powder-free DTF printing solution is now open for global testing and has already been applied in volume production for apparel, bags, home textiles, and other textile printing applications. It provides the digital printing industry with a complete powder-free solution that requires zero hardware modification, is environmentally safe, delivers excellent hand feel, and is ready for stable industrial use.