I see some things that are problematic.
1. First and foremost non-postscript OKI printers are not designed to for professional level final graphics output, they are office printers. You can get some OKI's that have postscript built in and in those cases they can be adjusted (via utility) to give decent "proofing" output, then the idea there is you send out the production documents to a high end printer that is very expensive.
So of course for heat transfer we intend to use the OKI as the final output for the graphic.
2. Adobe Illustrator is really designed for output to postscript output. This means the printer has postscript built in (like the C830) or you use a RIP software program to emulate Postscript.
Adobe explains that concept here and offers a workaround.
"Adobe Illustrator is optimized for PostScript printing. In fact, many of the Illustrator advanced features can only be described using the PostScript page description language. Non PostScript printers (for example, Hewlett-Packard LaserJets, Canon BubbleJets, or Epson Stylus) use printer description languages that are not full programming languages (for example, PCL or QuickDraw) and are unable to describe all of the objects and attributes in Illustrator artwork. Most non PostScript printers rely on display information, host computer resources, and proprietary printer drivers to relay print information to the printer.
When you print from Illustrator to a non PostScript printer, objects may not print, or may print incorrectly. The behavior may vary with different printers and with different versions of the printer software. Non PostScript printing problems can manifest themselves in many different ways, including (but not limited to) the following:
- Text or other objects are partially or completely missing from the page.
- A system error or freeze occurs."
Having said all that I have never been able to get AI to accurately print that PDI target file accurately no matter how I set it. I can get it to print accurately using Photoshop or Corel Draw, even using sublimation inks and toners.
I have a and use AI, but only to send out jobs to printing companies that have high end equipment.
There are also some issues with your setup which I detail below, but I doubt printing output using AI you are to get anything better than what you have.
The workaround really if you use AI is to export out to tif or pdf format and print from another application like PS or Corel Draw.
3. You have AI set to manage colors, but then you are also setting your OKI to manage colors, it should be only one adjusts the colors, not both. As you can see in the screen shot I attached AI doesn't offer an option so your non-postscript printer can manage the colors by itself. Corel and Photoshop will allow that.
"I have just calibrated my printer with Color munki and problem remains."
In order for that to happen you must let Illustrator handle the colors, then you set the ICC profile in the "Printer Profile" dialog in the AI print panel just below the "Color Handling" selection.
Your printing profile from your screen shot is using Adobe RGB 1998, that is not your ICC you made. You point to the ICC profile that you made there.
In that case AI would handle the color, you point to the ICC profile you made AND you turn off color management in the OKI driver, see the OKI driver screenshot for that.
Having said that I cannot get AI to print color accurate even if I have an ICC and turn off color management in the printer driver as you are supposed to. So AI could be useful to you for composing, then export out the file into a program like Photoshop for example.
Just FYI on all OKIs, especially for heat transfer you should force K toner only for 100% black, it won't fix grayscale issues but it will make sure pure black is not synthetic and making a composite black from CMY toners.
Also, a couple of key points ...
* You would need a profile made for each unique transfer paper.
* You would also make your ICC target(s) from actual transfers, not optically scanned from paper. There is some loss of "pop" usually using laser transfers once it is on the t-shirt, so there must be compensation also for that. I think Luis made that point in one his posts in this thread.
So you should try your actual printing from a different program then I can help you better there.