Mercerization can improve the utilization rate of dyes in the dyeing process, and reduce the discharge of washing wastewater. However, the effect and mechanism of mercerization is not clear on digital inkjet printing of cotton fabric. In this work, two kinds of cotton fabrics (original and mercerized) were used for reactive dye digital inkjet printing, and the color improvement mechanism of caustic soda mercerization was investigated. It was found that the crystallinity of cotton fibre was adjusted from 73.9% to 58.5% by caustic mercerization, and the breaking strength did not decrease compared with original cotton fibre. Thus, the accessible reactive hydroxyl groups and the wettability were enhanced for treated cotton fibres, which promoted the inks' wick into the fibres. Interestingly, the penetration of ink droplets between the yarns and fibres after caustic mercerization was decreased, thus the dyes mainly gathered on the surface of cotton fabric. The cotton fibres' cross section structure changed from flat oval to round, which increased the contact area between reactive dyes and fibres. At a certain amount of ink, the optimal K/S value of 23.47 was achieved for treated cotton fabrics, which was higher than that of untreated cotton fabrics (17.15). Meanwhile, the printed fabrics displayed good washing fastness, rubbing fastness and glossiness. This work has important theoretical guiding significance for producing high quality mercerized cotton fabric digital printing products and reducing printing wastewater discharge.
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