I’ve been working with print on demand sellers for years now, and honestly, it’s always exciting when the industry takes a leap forward, particularly in a way you don’t expect. We were all planning for things like AI and advanced automation to make an impact this year (and they are), but I don’t think anyone predicted how impactful a new printing option from a company like Gelato would be.
For me, Gelato is already one of the best POD vendors around thanks to its consistently high-quality prints, great range of premium and eco-friendly products (I love the art options), and it’s fantastic logistics network. The premium plan that gives you extra discounts and tools you won’t get from any other provider is another major perk.
This year though, Gelato has shown just how trend-aware it is, by launching the new Direct-to-Film (DTF) printing option (with a bunch of new product categories to boot). If you’re thinking: “so what?” stick with me, because I’m about to explain exactly why it matters.
Why DTF Printing Matters for Print-on-Demand Sellers
If you’ve followed the POD market over the last few years, you’ve probably noticed that the real growth isn’t happening in basic cotton tees anymore.
It’s happening in activewear, streetwear, and technical fabrics. The global performance apparel market alone is already worth nearly $2 trillion, but most POD sellers can’t access it, because their favorite printing method (DTG) only really works well with cotton.
That’s exactly why DTF is so great. Suddenly, it makes polyester tees and new materials like fleece and heavy blends available to merchants who want to expand their product lines.
Honestly, this is a huge moment. Not only are you getting an opportunity to branch out into streetwear, activewear, and other forms of premium (high value) apparel, but you’re getting it all from a vendor that’s already well-known for combining excellent quality, with smart design tools, fast shipping options and sustainability.
Why Gelato is Perfectly Primed to Lead the Way
I’ve said this before: Gelato behaves less like a POD provider and more like an actual production network. Their entire system is built around local fulfillment, predictable turnaround times, and tools that shave hours off the admin work most sellers drown in.
If you look at their track record, they’re usually ahead of the curve. They leaned into sustainability before it was trendy. They rolled out automation tools sellers genuinely use. Plus, they built a global footprint that actually works. So when a company like that adds DTF, it’s worth paying attention.
A new printing method like DTF takes work. You need color management, humidity control, consistent curing, properly sourced films, proper press pressure, all that stuff. Small print shops struggle with this every day. POD platforms struggle even more because they have to keep those standards steady across multiple regions.
Gelato is one of the few networks that already has the infrastructure to make that kind of rollout reliable. They’ve added this tech at the perfect moment, when Activewear and apparel purchases are just getting ready to spike at the start of the new year. It’s really great timing.
What Is DTF Printing?
If you’ve gotten this far and you’re still confused about what “Direct to Film” printing is (sorry about that), here’s what you need to know. It’s an alternative to DTG printing that tackles all of the common problems direct-to-garment printers have.
DTG’s biggest limitation is that it only behaves well on cotton. Go near polyester, nylon, or anything with stretch and the results start falling apart. You get washed-out colors, weak adhesion, cracking, or prints that look tired after a few gym sessions.
That’s not a minor issue. Polyester and synthetic blends dominate performance wear worldwide, and that’s a huge market to be missing out on.
DTF is the workaround we’ve needed for years.
Instead of printing directly onto the garment, the design is printed onto a film, coated with adhesive, and then pressed onto the fabric. That single shift makes the print far more adaptable to just about any kind of fabric.
If you need the simple version of how DTF differs from DTG:
- DTG bonds ink to cotton.
- DTF bonds a design to almost any fabric.
How Does Gelato DTF Printing Work?
You don’t really need to worry about the technical side of all this (that’s what Gelato’s for), but if you’re wondering how DTF works, here’s the straightforward explanation:
- Artwork prep: You upload your design the same way you would with DTG. Gelato’s editor flags issues early, too, which saves you from customer complaints before they happen.
- Printing onto film: A DTF printer lays down CMYK, then adds a white layer on top. That white layer is what keeps colors looking strong on dark or textured fabrics
- Powder adhesion: While the ink is still soft, a fine adhesive powder sticks to the printed areas. This is one of the reasons DTF holds up so well under washing and stretching.
- Curing: The powdered film gets heated until the adhesive melts and settles. This is a printer’s way of “locking in” the print before it ever hits a garment.
- Heat press + optional second press: The film is pressed onto the garment, peeled away, and sometimes pressed again for a smoother finish.
It’s pretty simple really, and Gelato handles it all for you, so all you really need to worry about is designs, customer service, and marketing your new line of DTF products.
DTF vs DTG: Which Should You Use?
| Factor | DTF | DTG |
|---|---|---|
| Best fabrics | Polyester, nylon, blends, cotton | Cotton and cotton-rich only |
| Print feel | Slightly raised, flexible | Soft, ink absorbs into fabric |
| Vibrancy on darks | Excellent (white base layer) | Good, but can fade faster |
| Stretch durability | High—no cracking | Moderate—can crack on stretch |
| Production variables | Fewer (more predictable output) | More (pretreatment, humidity, etc.) |
| Best product types | Activewear, streetwear, caps, polos | Classic cotton tees, hoodies |
Bottom line: DTF doesn’t replace DTG, it complements it. Use DTG for soft-feel cotton basics; use DTF for performance fabrics, dark garments, and products that need to survive heavy use.
Bottom line: DTF doesn’t replace DTG, it complements it. Use DTG for soft-feel cotton basics; use DTF for performance fabrics, dark garments, and products that need to survive heavy use.
Why Did Gelato Add DTF Printing?
Gelato is always making upgrades and improvements to what they offer POD sellers, which is part of why they’re one of my favorite brands. But you might still wonder why they added DTF now, particularly when they already do DTG so well (and most other POD companies aren’t bothering).
Really, the market pressure for this kind of printing method has been building for a while now. Cotton-only catalogs were fine five years ago, back when POD was still dominated by novelty tees and gift items. But the market has shifted.
Customers are buying more technical fabrics, more blended hoodies, more structured streetwear, and way more activewear. Polyester and poly-blends are now among the most common fabrics in mainstream apparel.
But, most POD sellers have been forced into a cotton-heavy lineup simply because DTG can’t handle anything else consistently.
Meanwhile, categories that do use synthetics, sportswear, outdoor gear, and lifestyle pieces, have been growing faster than the classic apparel market. Gelato has seen that gap, and they’re here to fix it.
DTF printing is their way of giving POD vendors more opportunities to branch out. You can still use DTG for your t-shirts and sweaters, but now you can experiment with a brand new range of products perfect for a new style of printing. Gelato has even introduced new category options like:
- Activewear: Sweat-resistant tees, long-sleeves, and quarter zips
- Streetwear: Fleece and heavyweight hoodies
- Headwear: Trucker caps and bucket hats
- Professional apparel: Durable polo shirts
Benefits of DTF Printing with Gelato
I know it might seem like I’m making a big fuss over a pretty small upgrade, but the introduction of DTF really is a great thing for POD companies. What you’re really getting from this is:
Fabric freedom so you can finally expand your product range
For years, POD sellers have lived inside a cotton bubble. Meanwhile, customers wear everything but cotton during their day-to-day lives:
- Polyester performance tops
- Nylon-blend outerwear
- Thicker streetwear fleece
- Structured hats
- Premium polos
DTF handles all of these without the usual print failures you get from DTG. The fabric barrier was the biggest limit on what POD sellers could offer. Remove that, and suddenly your store looks less like a print shop and more like a real apparel brand.
Strong color output and durability
Gelato’s DTG products already look amazing, and last well, but DTF takes the potential up a notch. Since the print sits on top of your garment (rather than soaking into the fabric), the colors stay vibrant for longer. The adhesive layer also gives you more longevity.
You can stretch out shirts and tops and you won’t have to worry about cracks or fading. On top of that, because you can print on thicker materials (designed to last longer), you can sell premium products that actually stand the test of time.
That’s the kind of thing that’s always going to impress your shoppers.
More predictable production
DTG has a lot of variables: pretreatment, humidity, garment color, fabric composition, moisture levels. Any one of those can ruin an otherwise good print. DTF has variables too, but fewer.
For sellers, this means fewer:
- Quality complaints
- Inconsistent batches
- “Why does this shirt look lighter than the last one?” emails
- Remakes eating your margins
On top of that, DTF costs don’t jump dramatically for dark garments the way they do with DTG. That makes pricing simpler, especially if you sell across multiple regions.
Sustainability, with nuance
No print method is perfect, but DTF eliminates a lot of the mess that comes with traditional setups. No screens, no liquid pretreatment, no washing chemicals down a drain. It’s cleaner and more controlled.
DTG still has strengths in this area, but DTF reduces waste by printing only what’s ordered. Plus, since Gelato handles the production side in proper facilities, the ventilation and powder-handling concerns are off your plate entirely.
A bigger catalog without a bigger workload
Honestly, this is the biggest advantage. DTF gives a solo creator the range you’d normally see from a mid-sized apparel brand: performance shirts, premium polos, fleece, hats, and more, without needing new workflows or equipment.
If you’re on Gelato+ already, the automation tools (Magic Mockups, Instant Collections, Price Navigator) mean expanding your catalog doesn’t add chaos to your week.
More products. Better fabrics. Higher average order value. Same amount of work.
How to Start Selling DTF Products on Gelato
Honestly, this is pretty simple, not much different from designing a DTG collection, but if you’re feeling nervous, here are a few tips:
- Start with DTF-Friendly Designs: DTF brings out bold shapes, sharp edges, and richer color than DTG, especially on dark or synthetic fabrics. So lead with designs that make use of that strength like shirts with logos, high-contrast artwork and clean typography.
- Order samples across different fabrics: One DTF sample doesn’t tell you much. Print the same design on three very different items, so it’s always a good idea to order samples and test them before you start selling.
- Build a small test collection first: Put together a collection with a few items, like a performance tee, hat, and a premium hoodie. You can use the same designs on all of them if you like, to see what your customers buy most.
- Use Gelato+ if you can: If you’re scaling, and taking advantage of Gelato+ for discounts, make the most of the extra benefits. Tools like Instant Collections, Magic Mockups, and Price Navigator save you a lot of time.
- Inform your customers: Always give customers tips on how to care for DTF products, like using cold wash settings, and cleaning them inside-out.
Also, market aggressively. Remember, not many POD providers offer DTF with the same level of quality you get from Gelato. Use that to your advantage.
Gelato DTF Deserves a Place in Your Store
When Gelato announced DTF, I think a lot of people honestly overlooked it. You might think it’s a small change to their catalog, but it’s massive. It’s a step that really introduces a brand new range of revenue-generating opportunities for today’s POD sellers.
You’re not stuck with the same t-shirts and sweaters anymore. You can expand into markets that are getting the most traction for fashion brands right now, and that’s a big deal.
If your store is just getting started, I’d recommend testing out a small collection first. Use DTF as a complement to your DTG catalog, and see what hits with your audience. Once you find out which products are really driving sales, expand from there. It’s that simple.
Frequently Asked Questions (FAQs)
What is DTF printing?
Direct-to-Film (DTF) is a printing method where designs are printed onto a specialized film, coated with adhesive powder, and heat-pressed onto fabric. Unlike DTG printing, which only works on cotton, DTF transfers cleanly onto polyester, nylon, blends, and other synthetic materials.
Is DTF printing better than DTG?
DTF and DTG serve different purposes. DTF works on any fabric and produces vibrant, durable prints that resist cracking and stretching—ideal for activewear and streetwear. DTG produces a softer hand-feel and works best on cotton. Most sellers use both methods depending on the product.
Does Gelato offer DTF printing?
Yes. Gelato now offers DTF printing across its global network of 140+ production partners in 32 countries. DTF products include performance tees, quarter-zips, polo shirts, heavyweight hoodies, fleece, bucket hats, and trucker caps.
What products are best for DTF printing?
DTF excels on synthetic and blended fabrics. Best-selling DTF products include moisture-wicking performance shirts, polyester activewear, structured caps, heavyweight fleece hoodies, and premium polo shirts.
How durable are DTF prints?
DTF prints are highly durable. The adhesive bond withstands repeated washing, stretching, and heavy use without cracking or significant fading—making DTF ideal for gym wear, activewear, and streetwear designed for frequent use.
What’s the difference between DTF and screen printing?
Screen printing requires creating physical screens for each design and is cost-effective only at high volumes. DTF prints on demand with no minimum order, produces less waste, and works on fabrics screen printing struggles with. For POD sellers, DTF offers more flexibility and lower upfront costs.
