In Direct-to-Film (DTF) printing, achieving crisp and vibrant prints depends on precise print head alignment. Misalignment can lead to issues like color misregistration, blurry edges, and banding. Common causes include mechanical wear, improper calibration, software settings, and paper route shifting—where inconsistent paper or film movement disrupts the print head’s position. Other factors like vibration, temperature changes, or frequent use can also affect alignment. Maintaining proper calibration ensures high-quality, consistent prints every time.
Some tools that can help streamline your alignment process include:
- Magnifying glass
- Handheld Wireless Digital Microscope
- Bright Lighting
When using Hosonsoft/PrintExp, it's important to perform the alignment calibrations in the following order for optimal results:
- Step Adjust
- Bidirec Adjust
- Head Space Adjust
- Step Adjust:
When you click the "Print Adjust" button, the printer will generate a test pattern displaying your current step calibration. This pattern consists of several sets of parallel lines, each labeled with different adjustment values. Your goal is to identify the pair of lines that align perfectly—or come closest to aligning. In some cases, multiple adjustments may be needed. The correct alignment occurs when two separate lines visually merge into a single, sharp line with no visible offset or ghosting.
Once you've identified the best-aligned set, enter the corresponding value into the software. This ensures precise print head movement and helps eliminate issues like banding or blurry prints.
After entering the value, it’s crucial to click "Calculate". This step applies your adjustment by adding it to the existing value displayed next to the Calculate button. Skipping this step will result in your changes not being saved or applied, so always make sure to hit Calculate before proceeding
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- Bidirec Adjust
When performing a Bidirectional Adjustment, the printer will print a test pattern consisting of line pairs while the print head moves in both directions—left to right and right to left. Your task is to identify the pair where the lines align perfectly, forming a single sharp line instead of two staggered or ghosted ones. This alignment confirms that the timing and positioning of the print head are properly synchronized in both directions.
Clicking the "Print Adjust" button will generate a test pattern showing your current bidirectional calibration. Based on the results, you may need to add or subtract from the current Bidirect Value, then retest until you achieve perfect alignment.
- Head Space
Head Space refers to the precise horizontal distance between each print head in a multi-head DTF printer. Proper head space alignment ensures that the different print heads—especially in CMYK + White setups—lay down ink in exactly the right positions relative to one another.
If this alignment is off, you may notice issues such as color overlap, gaps between layers (particularly between white and color), or shadowing. These problems can significantly affect image quality and consistency, especially with detailed or multicolor prints.
This adjustment is multi-step and must be done in the correct order:
Horizontal Head Space: Start with Horizontal Step 1, then move to Horizontal Step 2, as shown in the pattern.
Vertical Head Space: This is a single calibration, as seen labeled by #3 below.
Adjusting the Value for Head Space: Based on the test pattern results, you’ll either add or subtract from the existing Head Space value in the software. It’s important to note that you should only adjust the number that’s already present—never enter a new value starting from zero. The pre-filled number represents the printer's factory baseline or previous calibration. Starting from zero can disrupt the alignment, leading to inaccurate results.
If one head is printing slightly to the left or right of where it should, adjust the value accordingly. Small changes (e.g., ±1–3 units) can make a noticeable difference and significantly improve print quality.
Once you've completed all the calibration steps and are ready to test, begin by running a simple print. This will help you verify that the alignment is correct and ensure the printer is functioning properly before moving on to more complex prints.
Need additional help?
Please don’t hesitate to reach out to us for further assistance via email at service@ricoma.com or by visiting our support page at www.ricoma.com/US/support.