ABDULLAH NUR UDDIN

Lecturer, TECN.

WPE 311: Wet processing II

Special printing methods

»» Transfer printing:
Transfer printing is the term used to describe textile and related printing process in which the
design is first printed on to a flexible non textile substrate and later transferred by a separate
process to a textile.

»» Methods of Transfer printing:

a. Sublimation transfer:
This method depends on the use of a volatile dye in the printed design. When the paper is heated the
dye is preferentially adsorbed from the vapour phase by the textile material with which the heated
paper is held in contact. This is commercially the most important of the transfer printing methods.

b. Melt transfer
This method has been used since the 19th century to transfer embroidery designs to fabric. The design is
printed on paper using a waxy ink, and a hot iron applied to its reverse face presses the paper against
the fabric. The ink melts on to the fabric in contact with it. This was the basis of the first commercially
successful transfer process, known as Star printing, developed in Italy in the late 1940s. It-is used in the
so-called hot-split transfer papers extensively used today in garment decoration.

c. Film release
This method is similar to melt transfer with the difference that the design is held in an ink layer which is
transferred completely to the textile from a release paper using heat and pressure. Adhesion forces are
developed between the film and the textile which are stronger than those between the film and the
paper. The method has been developed for the printing of both continuous web and garment panel
units, but is used almost exclusively for the latter purpose. In commercial importance it is comparable
with sublimation transfer printing.

d. Wet transfer
Water-soluble dyes are incorporated into a printing ink which is used to produce a design on paper. The
design is transferred to a moistened textile using carefully regulated contact pressure. The dye transfers
by diffusion through the aqueous medium. The method is not used to any significant extent at the
present time

»» Some sublimation transfer printing:

a. Flat bed press:
Transfer machines for garments and garment panels have been developed on very similar lines
to conventional presses. In this machine, a paper is laid on the garment or garment panel on
the continuous belt. This is then moved under the heated plate B by a drive operated by a drive
operated by a foot pedal switch. The heated plate automatically lowers on to the paper/fabric
composite and is held there for a preset time and at a preset pressure. The plate then lifts and
the belt moves forward to allow the paper to be removed from the printed article, which is
added to a stack. Meanwhile a fresh garment or panel is arranged for the next print.

Fig: Flat bed press transfer printing.

b. Continuous transfer printing:

In this machine, the fabric and the pre-printed release paper pass in close contact with each
other round a large cylinder or drum (0.5-2m diameter). The two are held in contact by means
of an endless blanket under tension. The cylinder is heated electrically to 180-2200C and the
fabric in firm contact with the paper is passed over it for 15-20 seconds. Thus the pattern on
the paper is transferred on to the fabric by sublimation. The operation is continuous. The
output is 15m per minute.

Fig: Continuous transfer printing.

» Flock printing:
Flock printing is a process in which a flock i.e. a mass of short fibres is fixed on to cloth by
means of an adhesive to form a printed pattern. It produces a pile or velvety effect on the fabric
similar to the pile obtained by raising the fabric by machines. The process is also called velvet
printing.

Short fibre of 1mm in length are cut from natural or man made fibres are used.
Two types of flocks are used
a. Random-cut flock
b. Precision-cut flock
Random cut flock is obtained from waste fibre and fabric clippings which are reduced to a mass
of very short fibres by cutting or grinding and then screeing to eliminate dust and unduly long
fibres.
Precision cut flock is generally obtained from rayon and nylon filaments by cutting the dyed tow
in desired lengths. The flock i.e. short fibres, has only two dimensions- length and thickness.

»» Methods of flock printing: Flock printing methods can be two types:

a. Beater Bar Method:
In this method, the coated fabric is held tight on a conveyor belt, the flock is fed to the cloth
bye means of hoppers. The cloth is rapidly beaten by beater bars and vibrated to make the
fibres stand on ends and become firmly fixed in the adhesive. The beater bars below the cloth
rotate rapidly and rub against the backing material therby generating static electricity which
makes the fibres stand on ends. The unfixed flock is removed by means of vacuum suction. The
number of fibres that are oriented perpendicular to the surface of the cloth by this method is
not very high with the result that the flock density is low.

Fig: Beater bar flock printing

b. Electrostatic method:
Electrostatic flocking utilizes an electric charge to orient fibres and promote their perpendicular
alignment. This technique optimizes the results obtained with longer fibre. In this method, the
adhesive coated substrate passes through a high voltage electrostatic field. An Electrode is
utilized to give the flock fibre a charge. The charged fibres become aligned with the electric
field lines of force and are attracted to the grounded electrode. The flock moves towards the
adhesive coated substrate and becomes embedded. Fibres are adhered perpendicular to the
surface giving a dense, pile finish.
 Fig: Electrostatic flock printing

»» Jet printing:
inting is a process where aqueous print medium i.e. ink based printing instead of print
Jet printing
paste by printer which uses electric charge or impulse system in its working to create pattern
on fabric.
»» Types of inkjet printing:
Jet printing system used forr textiles may b
be classified as
a. Selectively
electively deflected charged-drop(Continuous
charged drop production) or
b. A drop on demand(DOD)

a. Continuous drop production/ Continuous ink jet printing:

In this machine an ink reservoir is used. From ink reservoir ink is supplied. A Pump is used to
carry the ink from ink reservoir to piezoelectric crystal from where inkk comes out as droplets
through ink nozzle. Then the charging tunnel charges the droplets that are not need on the
fabric according to the instruction from computer.
computer. Charged droplets are deflected into a gutter
then to ink reservoir by the Deflection plates, while uncharged droplets ts fly straight onto the
fabric and print is done.

Fig: Continuous inkjet printing

b. Drop on Demand ink jet printing:
DOD printers depend on some means of imparting an electro mechanical or thermal shock
impulse to a printing ink, which is held at atmospheric pressure close to the jet orifice.
DOD printing can be two types:

a. Bubblejet types: In bubblejet printers ink drop ejection follows the application of a very short
voltage pulse to a tiny resistor etched within each channel of the print head. This pulse
produces a local temperature of about 3500C within a few microseconds and the coalescing
micro bubbles of steam formed displace a corresponding droplet of ink from the jet orifice,
after which the bubble collapse. The ejected droplets of ink have a diameter of about 40µm

Fig: Bubblejet system

b. Piezo types: In piezo actuated print heads the impulse is provided electro-mechanically. An
piezo element is attached with a vibrator plate. When pulse applied it cases the individual piezo
element + vibration plate forming the channels leading to the jet orifices to bulge, thus
producing ink drop ejection.

Fig: State of piezo element without voltage supply. Fig: State of piezo element when voltage is applied.

Fig: Before ejection of Droplets. Fig: Ejection of droplet.

» Burn-out Printing:
Burn out printing is the production of a pattern on a fabric by printing with a substance that
destroys one or more of the fibre types present. A paste containing chemicals capable of
destroying one of the fibre components is used in this process. It is also called devore printing.

»» Burn-out Printing of PC Fabric:

1. In burn out printing, cellulose portion of PC fabric is removed with the desired properties by
using 70-75% strong H2SO4.
2. Burn out printing may be carried out in following two methods-
a. By jigger
b. By Padding mangle

3. Recipe:
H2SO4- 70% in strength
Urea -10gm/L (Padding mangle)
Time - 45 min (Jigger), 120 min (Padding mangle)
Temp - Room temperature
M:L - 1:15

4. After burn out, fabric is washed thoroughly to remove degraded cellulose & remaining H2SO4.
5. Then it is neutralized with Soda ash & bleached with H2O2.
6. The fabric is washed again and dried.

Advantages of Burn-out Printing:

1. Burn out printing is used to make fashion dresses and decorative purposes.
2. No special or costly machine is required.
3. This style was originally used on cotton to give novel dress fabric effect.

Disadvantages of Burn-out Printing:

1. If the process not properly controlled the whole fabric will be damaged.
2. May impair tensile strength & stability of fabric.
3. It can't be corrected.
4. The highly concentrated chemicals are harmful to operatory & machinery.
5. Only blended fabrics can be printed.