TPU (Thermoplastic Polyurethane) powder is the critical chemical bonding agent in Direct-to-Film (DTF) printing. Formulated as fine white or black microscopic polymer granules (typically 80 to 200 microns in diameter), the powder is dusted onto the wet digital ink on PET transfer film. In the infrared oven, it melts at 115°C into a flexible, stretchable adhesive matrix. When heat-pressed at 160°C, the melted TPU flows around individual yarn fibers, anchoring the print with high tensile stretch-recovery and wash resistance.
The Polymer Science of Hot-Melt TPU Adhesive
Thermoplastic Polyurethanes are block copolymers consisting of alternating hard and soft segments. The soft segments provide extreme elastic flexibility and rubbery elongation, while the hard segments provide chemical toughness, abrasion resistance, and laundry wash stability.
Selecting the proper particle size is critical: fine powder (80–120 microns) is ideal for intricate vector artwork, floating text, and lightweight summer t-shirts because it deposits a thin, butter-soft glue layer. Medium powder (120–200 microns) is required for deep-pile fabrics like 350 GSM fleece hoodies and pique polo knits to fill the valleys of the texture.
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