With different dot overlap distance and surface property, the inkjet line tracking on substrate will present different line width. To be a fabrication process, for example, form circuit on flexible substrate by ink-jet printing technique, the line width will dominate by the factors of image transfer loss, the pattern type of image and its overlap rate, and the hydrophile-hydrophobic surface property. This paper discussed the image transfer loss and the effects of pattern for direct ink-jet patterning method of forming circuit. A standard file (Gerber RS274X) for printed wire board (PWB) is first transferred into half-tone image, and prepared for discharging by ink-jet printing control. By image segmentation, the image characteristics are abstracted into sub-patterns. Those distinguishable patterns include circle via, horizontal trace, slant trace, vertical trace, square, and blank. The system consists four major phases; the first step is segmentation of Gerber image into sub-patterns in raster data, the second step operates superposition on the abstracted sub-patterns, the third step performs verification and inspection, and the final step optimizes the printing route. Experimental results demonstrated the necessity of the proposed algorithms, and data showed that the variation of circuit line width can be controlled within ±15%.