Stencils

Stencil printing is a versatile technique that can be used on screen printing clothing many different materials and formats, from custom clothing to posters and signage. Using a mesh screen, ink and a squeegee, it’s possible to expertly transfer a stencilled design onto any flat surface.

The first step in screen printing is coating the mesh screen with a light-reactive emulsion. Then, a piece of acetate with the desired design is placed on top and exposed to bright light. This hardens the emulsion on the part of the screen that covers the stencil, while leaving the rest of the screen susceptible to ink.

This process is crucial, as under or overexposure can affect the print quality and durability of the stencil. Drying the screens correctly in a dark and controlled environment is also essential.

Ink

There are several different kinds of screen printing inks depending on the type of fabric used. Some are water-based and others are plastisol based.

A water-based ink is one that soaks into the fibers of the cloth rather than sitting on top of it like a plastisol ink. This results in a softer feel and a subtle sheen. These inks are also easier to clean up, though proper cleaning procedures are still essential.

Plastisol inks are the mainstay of the industry and provide the greatest range of color options and printability. They can be printed on both light and dark garments (though darker fabrics will require a special low-bleed white under base). These inks are also easy to work with as they dry quickly once the screens have been cleared.

Screens

Whether you're a seasoned pro or just starting out, the screen printing industry can be overwhelming. There are so many different things to know and learn, from the equipment and materials to the entire process.

The screens used in screen printing are metal frames covered with a mesh fabric. The blank screens are coated with a light-sensitive emulsion, then the film positive is aligned on top. The black areas of the film block out light, leaving a soft area of emulsion on the screen that will reflect your design.

Higher mesh counts (like 156-64 or 61-30) are good for thicker inks, such as high density glitter inks or opaque inks. Thicker inks also help the designs stand up to repeated washing, making screen-printed apparel a great choice for teams and events or for promotional merchandise.

Platens

The garments to be tshirt screen printing are laid on lightly tacked platens (also known as shirtboard, print bed or printing table). Platens come in a wide variety of materials, sizes and shapes. The material that you choose will have an impact on your production, quality and even your ability to do business in the screen printing industry.

An essential piece of equipment for most shops is a flash cure unit. These units help to partially cure or gel the plastisol inks used in screen printing. This allows you to print white underbases and overlapping colors without having to wash out your screens as often. Platen tape is a paper based product that can be applied to the platen to prevent lint build up. This saves time and money as the tape can be easily reapplied.

Printing

Screen printing is a stencil technique that uses a mesh-screen (originally made from silk) with ink or paint. The non-printing areas of the fabric are blocked out with a rubber blade known as a squeegee, and ink is forced through the screen onto the substrate.

With the use of special plastisol inks, screen printing can produce a wide range of effects including raised print, specific textures, and exact color matching. It also offers a good level of scalability for larger orders and can be used on multiple materials.

Digital printing offers excellent design consistency, cost reduction for smaller orders, and breathable prints. It also works well with both natural and synthetic fabrics and offers great flexibility when it comes to unconventional design placements. After applying the digital design, the shirt goes through a curing process (typically using a heat press or conveyor dryer) to set the dye and make it resistant to washing and physical wear and tear.