A record-setting Impressions Expo, cutting edge machine embroidery and yet more direct-to-film (DTF) tech
Alas, for those hoping for “less interesting times” following the turmoil of the past few years, the world, for better or worse, remains as “interesting” as ever. That said, the good news as far as the custom decorated-apparel business goes is that there’s just no keeping down the decorators of the world—as was evident at this year’s first two Impressions Expos (impressionsexpo.com).
The 2025 Long Beach expo was one for the record books, with over 300 exhibitors reserving 124,000-square-feet of floor space. Photo courtesy of Impressions Expo
The first expo of the year, in Long Beach, California, was literally one for the record books, with over 300 companies reserving an incredible 124,000-square-feet of floor space, making it the biggest Impressions Expo ever. The show was literally sold out. The energy was also one for the record books, with packed rooms at the show’s educational conference series, and hundreds more checking out the Ink Kitchen’s Shop Talk stage out on the show’s main floor.
As for the year’s second Impressions Expo in Atlantic City, New Jersey, while not as big as the Long Beach event, it was no less promising, with respect to the industry’s future especially. Indeed, afterward many exhibitors were heard to say it was just as good or even better in terms of the number of leads generated and sales made as Impressions’ premier Long Beach event—high praise, indeed!
As for the products and services on display, which included more than a few industry debuts, suffice it to say, the industry as whole is continuing to steam full speed ahead. Blank apparel, sustainability, the latest decorating tech, you name it: recent trends not only remain very much in play, but continue to build momentum. The end result is an industry with as bright a future as ever, come what may.
Direct-to-film (DTF), Digital Decorating
Not surprisingly, digital decorating was once again the big story, especially in the area of direct-to-film, or DTF. Indeed, so ubiquitous has DTF become, it’s hard to believe the technology was still considered “cutting edge” only a few short years ago.
Yet another sign of the times: M&R’s second new DTF printer in as many years. Photo courtesy of Impressions Expo
Everywhere you looked at both expos (and at the 2024 Impressions Expo in Texas last October, as well) you couldn’t help but see further evidence of this fact. Printers, heat presses, DTF transfers and custom transfer services, you name it—DTF was and looks to continue to be evident everywhere.
In terms of printer tech, among the standouts were the new Epson SureColor G6070 DTF printer, the company’s first all-DTF system, following in the footsteps of the company’s SureColor F1070 hybrid DTG (direct-to-garment)/DTF system. Long a provider of the basic nozzle technology found in countless machines across the printing world, the new SureColor G6070 is especially notable for its ease of maintenance, a key factor when DTF printing at scale.
Another notable debut was M&R’s new Quatro 68 DTF printer, a larger version of the same type of Quatro printer introduced in 2024. Clearly, the company’s foray into commercial-scale DTF printing is more than just a whim. On the contrary, the renowned screen-printing equipment supplier clearly means business. Further evidence of this fact could be found in the company’s Quatro Cutter X DTF transfer film cutter, designed to automatically cut the continuous line of transfers coming off a DTF printer into workable sheets—a big time saver no matter what size shop you’re running.
ROQ’s new IMPRESS automated heat-press system. Photo courtesy of Impressions Expo
Then, of course, there’s the new fully automated ROQ IMPRESS “system,” composed of what is in essence a heat-press version of the screen-printing autos the company has long produced and a trio of complementary systems: the FEED, PEEL and PULL, which pretty much do what their names say, i.e., automatically place each transfer; remove the backing material when heat-pressing is complete; and then remove the fully decorated shirt, leaving little more for an operator to do other than thread each garment onto a platen.
Meanwhile, the battle royale that is the current state of the custom transfer industry continues, unabated, as the major players in this area all continue slugging it out in the form of a seemingly never-ending stream of new products and services—including both a wide range of transfer types and an equally wide range of shipping options, making their products cheaper and easier to work with than ever.
613 Originals, for example, was touting such new products as its new DTF Hybrid Heat Transfer and its White Puff and Full Color glow in the dark lines.
Similarly, Ninja Transfers, after bursting onto the scene only a couple of years ago, continues to push the envelope. New initiatives on offer included everything from the company’s “AI Upload” design tool to the expansion of its film offerings with an array of new styles, including glitter, glow-in-the-dark and the company’s newly added gold and silver foil films line.
In the wake of Impressions Expo Atlantic City, Ninja Transfers also recently announced the launch of a new business it’s calling Ninja Blanks, a curated line of premium blank apparel—the company’s latest initiative designed to make getting involved in heat pressing as easy as possible.
Finally, there was industry stalwart STAHLS’ and it’s Hotronix heat press and Transfer Express custom transfers lines. As is the case with its competitors, STAHLS’ had a number of new products on offer, including its EasyRip option, which allows decorators to separate a set of ganged transfers by hand. Making an equally big splash was STAHLS’ new Fulfill Engine, an “all-in-one” online business management software system encompassing everything from e-commerce and online company stores to the nuts and bolts of shipping and receiving—not just for heat press decorators but decorators of all kinds, including embroiderers and screen printers.
Machine Embroidery in the Computer Age
Speaking of the embroidery business, equipment and materials suppliers continue to push the envelope in this area as well, with a focus on both ease-of-use and sustainability.
Embroidery systems specialist Melco is making waves with its Fusion e-commerce and embroidery software system, and the Summit 16-needle embroidery machine. Photo courtesy of Impressions Expo
Case in point, Melco debuted not one but two new products, the Melco Fusion e-commerce and embroidery software system, and the Melco Summit 16-needle embroidery machine. The former is described as “a cloud-based web service hosted by Melco that generates product previews and embroidery-ready files using data submitted by users on your e-commerce website.” The latter, among other advances, includes a laser alignment and positioning system, and a built-in barcode reader to ensure the right garment gets the correct design in every case.
Not to be outdone, Germany’s ZSK was also touting a pair of cutting-edge systems—it’s super-fast Racer-R embroidery machine and the newly revamped EPS Hoop Station. Alas, the Racer-R system got held up in transit and couldn’t make it to the Long Beach show in time. Suffice it to say, though, the new system promises to be a powerful piece of equipment and then some, offering stitching speeds of over 2,000 stitches per minute. Available in both single- and multi-head configurations, the Racer-R is also designed to reduce vibrations and noise levels with an eye toward creating a safer and more comfortable work environment. A modular embroidery head facilitates quick replacements as well, ensuring minimal down times.
As for the EPS Hoop Station, this nifty piece of equipment allows operators to visualize how best to position a garment prior to stitch-out by projecting an image of the design to be embroidered onto an accompanying hooping jig, thereby minimizing placement errors. Think the same basic concept as STAHLS’ award-winning ProPlace IQ system, which essentially does the same thing when heat pressing.
Finally, there was Ricoma’s new 20-needle embroidery machine line, featuring a 10.1-inch touchscreen user interface, and Madeira USA’s new Polyneon Green Thread. The latter, coming fast on the heels of the company’s sustainable E-ZEE Cut Green backing product, is made entirely out of 100-percent recycled post-consumer PET bottles while still providing the same strength, brilliant colors, shine and overall outstanding performance of the company’s other threads.
The new Ricoma machines, which are available in single-, double- and three-head configurations, feature the combination of an oversized embroidery area to accommodate larger designs and 270-degrees of rotation for “ear-to-ear” cap embroidery.
Clearly, the embroidery industry is doing everything it can to make sure DTF doesn’t get all the attention!
Blank Apparel, Direct-to-Garment (DTG) and Sustainability
Returning to digital decorating for a moment, as is the case with its move into DTF, ROQ is continuing to show its commitment to DTG with the company’s new, fully revamped NOW “100-percent digital printing machine.” Capable of processing up to 250 garments per hour, the NOW includes everything from a pre-treat component to a pressing station, flash-cure station and multiple print stations for both white ink and full-color—basically everything you need for fast, efficient high-quality decorating.
Let the new ROQ NOW digital decorating system serve notice: digital decorating is here to stay. Photo courtesy of Impressions Expo
As for screen printing, it feels a bit strange not getting to what once served as the industry’s preeminent decorating technology until the latter part of a survey article like this. However, it feels like it has been put on pause for a bit in terms of basic printing technology. Today’s autos, for example, remain paragons of precision, productivity and efficiency; same thing with today’s screen production tech—one of the reasons screen printing remains a leading decorating method despite the inroads being made by DTF and DTG.
That said, one area in which the industry continues to see gains is in screen reclamation. Of particular interest is the work being done to make the process as sustainable as possible, with an eye toward keeping as many toxic chemicals as possible out of the waste stream.
Given today’s tight labor market, this is also an area in which equipment manufacturers are doing everything they can to make the job as pleasant as possible in an effort to help decorators retain workers. The result has been such automated systems as M&R’s ECO-TEX modular automatic screen cleaning and reclaiming system; ROQ’s newly introduced JetBlack automated screen reclamation system; and the extensive line of screen reclamation systems and chemicals being produced by such companies as Easiway Systems and Bluewater Labs.
ZSK’s newly revamped EPS Hoop Station helps ensure each and every garment is hooped as it should be. Photo courtesy of Impressions Expo
Finally, in the world of blank apparel, the industry’s leading manufacturers seem to be continuing to work along two separate but often overlapping, tracks: ease of decoration and sustainability.
With respect to the ease-of-decoration side of the equation, one of the standouts for 2025 has been Gildan’s new Plasma Printing tech, which works by integrating a series of specialized softeners directly into a garment’s fabric as a part of the manufacturing process. The result is a garment that minimizes or even eliminates the need for pre-treatment when DTG apparel printing, long the bane of DTG decorators, especially those lacking the resources for systems like the ROQ NOW.
No mean feat from a production standpoint—or in terms of the exact chemistry that makes it possible—Gildan’s Plasma Printing tech is the kind of breakthrough that may prove to be a real game-changer. It will be interesting to see the impact of this latest move by Gildan’s, both on its competition and the decorated-apparel industry as a whole.
As for the sustainability side of the equation, it’s great to see the blank apparel industry’s efforts to minimize the environmental impact of its products not just continuing but becoming even more entrenched. Whether you’re talking headwear, fleecewear or the latest crop of tees, green materials and manufacturing processes remain the name of the game.
Among the standouts would be Italy’s Atlantis Headwear with caps like the Fiji, a structured five-panel baseball cap made of 100-percent recycled polyester complete with a “Retraze” bill made of recycled plastic waste removed from the world’s oceans; Lane Seven’s continued commitment to sustainability with its “Future Fleece” line, made of 100-percent recycled yarn; Otto Cap’s new “5 Panel Pro Style Baseball Cap” made of recycled Taslan Nylon; S&S Activewear’s new Pro-Flex performance fabric composed of 60-percent polyester pin-dot mesh and 40-percent Sorona, a partially plant-based polymer; and Allmade’s newly released Unisex Organic CVC Fleece Pullover Hoodie, incorporating 60-percent organic combed ring-spun cotton and 40-percent recycled polyester.
Hanes celebrated the 50th anniversary of its Beefy-T T-shirt line at the Long Beach show with a fun heat-pressing activation. Photo courtesy of Impressions Expo
Kudos as well to Hanes, which celebrated the 50th anniversary of it Beefy-T T-shirt with a magnificent heat-pressing activation at the Long Beach show and the release of a new Beefy-T Retro Street Tee. Same thing for Live & Tell by L.A.T.’s Vintage Wash line, which employs a proprietary pigment dying process that results in fabric that is comfortable as it is easy to decorate; and Gildan’s Comfort Colors line, also marking its 50th anniversary.
Finally, a shout out to the Chinese company S.E.C. Accessories Limited and its fully automated, self-contained heat-press robot. Somewhat analogous to the mixed-drink robots that have been around a few years now, the system may not yet be ready for prime time in terms of mass production—especially in light of the many advances in automation already mentioned. Nonetheless, it would make for a heck of an on-site novelty at, say, sporting events. Then again, the way the industry is proceeding these days, who knows?
