Water Transfer Printing Film Production Process - Step-by-Step Guide

This guide details the full manufacturing workflow of water transfer printing film, with a focus on precision control for consistent quality and vivid pattern transfer effects.

Pre-Production Preparation

Pattern Design & Digitization

*Create or source target patterns (wood grain, marble, geometric, floral, etc.) using graphic design software (e.g., Adobe Illustrator, Photoshop).

*Optimize patterns for printing: adjust resolution (≥300 DPI), color saturation, and size ratio to match the final application scenarios (e.g., mirror frames, furniture surfaces).

*Conduct a sample color proof to confirm color accuracy before mass production.

Raw Material Selection

Base Film: Choose water-soluble polyvinyl alcohol (PVA) film as the carrier. Select thickness (usually 20–50μm) based on application needs—thicker films for large-area transfers, thinner ones for curved surfaces.

Ink: Use specialized solvent-based or UV-curable ink that adheres well to PVA film and resists water during the transfer process.

Protective Coating: Prepare transparent acrylic or polyurethane resin coating for pattern protection and scratch resistance.

Core Production Steps

Pattern Printing

-----Load the PVA base film rolls onto a specialized gravure or flexographic printing machine (gravure printing is preferred for high-precision, high-volume production).

-----Print the digitized patterns onto the PVA film surface in a dust-free workshop to avoid dust particles causing print defects.

-----Control printing speed (typically 10–30m/min) and ink temperature to ensure uniform ink coverage and sharp pattern edges.

Protective Coating Application & Curing

-----For solvent-based coating: Use hot air drying (temperature 60–80℃, drying time 2–5min) to evaporate solvents.

-----For UV-curable coating: Expose to UV light (wavelength 365nm) for 1–2min to achieve instant curing. This step enhances pattern durability and water resistance.

-----Apply a uniform layer of transparent protective resin to the printed pattern surface using a roll coater. The coating thickness is controlled at 5–15μm.

-----Cure the coating:

Slitting & Cutting to Specification

-----Use a slitting machine to cut the large printed film roll into standard widths (e.g., 50cm as your requirement) based on customer or market needs.

-----Cut the slit rolls into fixed-length sheets or wind them into small rolls for easy packaging and transportation.

-----Ensure the cutting edges are flat and free of burrs to prevent film tearing during use.

Post-Production Quality Control & Packaging

6. Comprehensive Quality Inspection

• Visual Inspection: Check each batch for pattern defects (smudges, missing parts, color deviation), coating uniformity, and base film integrity.

• Functional Testing: Take sample films to conduct a water transfer test on a test substrate (e.g., plastic plate) to verify pattern transfer rate, adhesion, and scratch resistance.

• Batch Sampling: Inspect 3–5% of each production batch; reject the entire batch if the defect rate exceeds 1%.

• Packaging & Storage

• Package the finished film rolls/sheets in moisture-proof plastic bags, then place them in cardboard boxes with desiccant to prevent PVA film from absorbing moisture and sticking together.

• Label each package with product information: pattern type, width/length, batch number, production date, and storage instructions (store in a cool, dry place at 15–25℃, avoid direct sunlight).

Key Notes

• The entire production process must be carried out in a dust-free, low-humidity environment to avoid affecting print and coating quality.

• Adjust process parameters (printing speed, curing temperature) based on different pattern types and raw material specifications.