Screen Printing Process, Types and Materials Find the Best Method

So you want to learn about screen printing, huh? Well, you’ve come to the right place. Screen printing is a fun and versatile way to print graphics on all kinds of surfaces. Whether you want to print t-shirts for your band or create custom wall art for your home, screen printing allows you to make high-quality prints with vibrant colors.

The screen printing process involves creating a stencil and using it to apply layers of ink onto the printing surface. The stencil blocks some areas and allows ink to pass through open areas, creating your design. There are several ways to create stencils, like using photo-emulsion, vinyl cutters, and laser cutters. The type of stencil and ink you use depends on what material you want to print on.

Screen printing does require some equipment and a bit of a learning curve, but the results can be very rewarding. With some practice, you’ll be creating colorful prints in no time. This article will walk you through the basic steps of screen printing so you can start making your own custom designs. Let’s dive in!

The Screen Printing Process: How It Works

To understand how screen printing works, let’s walk through the basic process.

First, a screen is prepared. A fine mesh screen is coated with a light-sensitive emulsion. Once dry, a film positive with your design is placed over the screen and exposed to light. The light hardens the emulsion, except where the design blocks it.

2. Next, the screen is washed. The unhardened emulsion is washed away, leaving your design as open mesh. This creates the stencil that will be used to apply ink.

3. Then the screen is placed over the item to be printed. Ink is applied to the top side of the screen. Using a squeegee, the ink is pushed through the open mesh onto the item below.

Read Also: Types of Fabric Printing: Find Right Method for Your project

4. Multiple screens can be used to apply different colored inks to create multicolored designs. Screens also come in different mesh counts, controlling how much ink passes through. Finer mesh gives more detail while coarser mesh allows more ink to pass, useful for larger prints.

5. The final step is curing. The ink needs to be cured, usually by heat setting, to bond it to the material. Curing makes the print durable and permanent.

And that’s the basic process for how screen printing transfers your designs onto t-shirts, posters, and more. With some practice, you’ll be creating your own custom prints in no time!

Types of Screen Printing:

When it comes to screen printing, you’ve got options. The three main methods are flatbed, rotary, and roll-to-roll.

Flatbed screen printing:

Flatbed screen printing is probably what you picture when you think of screen printing t-shirts. It uses a flat, stationary screen over a flat surface. It’s great for printing on rigid materials that can lay flat, like wood, glass, and of course, t-shirts.

Rotary screen printing:

Rotary screen printing uses a cylindrical screen to print onto long, continuous rolls of fabric or other flexible materials as they pass through the press. This high-volume method is ideal for wallpaper, gift wrap, and textiles.

Roll-to-roll screen printing:

Roll-to-roll screen printing also uses large rolls of material but prints on a flatbed with rollers to feed the material through. This allows printing on materials that can’t bend or wrap around a cylinder. Roll-to-roll screen printing works well for banners, posters, and vinyl decals.

The method you choose depends on the material you want to print on and the volume of your work. Small scale? Go with flatbed. High volume textiles? Rotary is your friend. Large format but flat? Roll-to-roll will have you covered. With the right technique, screen printing can put your designs on almost anything.

Screen Printing Inks and Materials:

Plastisol Inks:

Plastisol inks are the most common type used in screen printing. They contain PVC particles suspended in a plasticizer, giving them a thick, paste-like consistency. Plastisol inks require heat to cure and harden after printing. They are very opaque, durable and flexible. Plastisol inks can be used to print on cotton, polyester, nylon and other fabrics.

Water-Based Inks:

Water-based inks, also known as acrylic inks, use water as the solvent. They contain acrylic polymers and pigments. Water-based inks air dry or can be heat cured. They produce soft prints and are more environmentally friendly since they are water-soluble. However, they may require special screen printing equipment to prevent the ink from drying in the screen. Water-based inks work on both light and dark fabrics.

Discharge Inks:

Discharge inks actually remove the dye from the fabric, creating a vintage faded look. They contain bleaching agents that break down the fabric dyes upon heating. Discharge inks require a discharge base to activate the bleaching agents. They produce very soft prints with a washed out, distressed appearance. Discharge inks only work on dyed, colored fabrics since they require dyes to remove. They may weaken the fabric over time due to the bleaching process.

Read Also: Block Printing: Everything About This Age-Old Craft

The specific ink and material you choose depends on the desired print effect, fabric type, cost, equipment and environmental factors. Do some testing to determine what works best for your needs. With the variety of options available, you can achieve any print style you want.

Screen Mesh:

Choosing the Right Mesh Count For Design

Mesh Count:

The screen mesh count refers to the number of threads per inch in the screen fabric. The higher the mesh count, the finer the threads are, creating a higher thread density. Choosing the right mesh count for your design depends on several factors:

A higher mesh count, like 230-305, will produce a higher resolution print with finer details, which is great for complex designs with small text or thin lines. However, the ink will pass through the screen more slowly, requiring a longer print stroke and potentially multiple passes to fully transfer the image.

A lower mesh count, like 86-156, has thicker threads so the ink passes through more easily, allowing for a faster print stroke. This works well for simple designs with large block areas of color. However, the lower resolution will lack fine details and crisp edges.

For most screen printing projects, a mid-range mesh count of 156-230 is a good place to start. This provides enough detail for most designs while still allowing the ink to pass through efficiently. You can then adjust based on your specific design needs for future prints.

Other factors to consider are the type of ink you’re using, the material being printed, and the level of detail in your designs. Test different mesh counts to determine what works best for your application. In the end, choosing the right mesh count, along with the appropriate emulsion and ink, will help you achieve clean, crisp prints every time.

Curing and Drying:

Ensuring Proper Adhesion of the Ink

Once your screen print design has been transferred to the shirt, the final step is curing and drying the ink to ensure proper adhesion.

Heat Setting:

Heat setting the ink fuses it to the fabric using a conveyor dryer or heat press. The shirt passes through the dryer on a conveyor belt and is exposed to high heat for 30 to 90 seconds depending on the ink and fabric. The heat causes a chemical reaction in the ink, bonding it to the fibers. For small runs, a heat press can be used. Place the screen printed shirt onto the platen of the press and close for 10-30 seconds.

• Make sure to follow the recommended time and temperature for your ink and fabric type. Too little heat won’t properly cure the ink, while too much can scorch the fabric.
• Heat setting should be done within 24 hours of printing for the best results. The longer you wait, the less effective the heat curing will be.

Air Drying:

If you don’t have access to a conveyor dryer or heat press, air drying is an option. Hang the screen printed shirts to dry completely, at least 24 hours. While air drying will cure the ink, it typically results in a softer hand and less durability compared to heat setting.

• Avoid stacking the shirts on top of each other while air drying or the ink may not cure properly where the shirts contact each other.
• Turn the shirts inside out before hanging to dry for the most even ink coverage.
• Air flow and humidity levels can affect drying time. Provide good ventilation and avoid very humid conditions.

Following the proper curing techniques for your chosen method helps ensure a quality print with maximum wash durability and longevity. With care and maintenance, a well-cured screen print can last for many washes.

QnA Related to Screen printing:

What is the best method of screen printing?

Screen printing method

When it comes to screen printing, there are a few methods to choose from. The best method for you depends on the type of design you want to print and the number of prints needed.

• For less work

For small runs or complex prints with lots of colors or gradients, manual screen printing is ideal. This involves placing the screen over the item and using a squeegee to push ink through the open areas of the screen. This requires more time and labor but offers the most control over the final results.

• For more demand and work

For larger runs, automatic screen printing machines are the way to go. These use mechanical squeegees and platens to quickly print each item. The most common types are rotary screen printers and flatbed screen printers. Rotary screen printers are very fast but can only print on cylindrical items like bottles or cans. Flatbed screen printers can print on flat items of various shapes and sizes.

In the end, you need to weigh the pros and cons of each method based on your specific needs. Manual screen printing offers high quality but lower efficiency, while automatic screen printing is very efficient for high volume but may lack the precision of manual printing. By understanding the different screen printing techniques available, you can choose the one that will work best for your project.

What chemical is used in screen printing?

To create those vibrant designs on t-shirts and other goods, screen printers use special chemicals and inks. The most important chemical in the screen printing process is the emulsion.

The emulsion is a light-sensitive liquid that is used to create the stencil on the screen mesh. When exposed to light, the emulsion hardens, creating the stencil that will block ink from passing through certain areas of the screen. The areas of the screen not exposed to light remain soft, allowing ink to pass through.

There are two types of emulsions: diazo and dual-cure.

• Diazo emulsions use ammonia vapors to harden the emulsion after exposure to light.

• Dual-cure emulsions use a chemical hardener in addition to light exposure. Dual-cure emulsions tend to be more durable and chemical-resistant.

In addition to the emulsion, screen printers use inks, solvents and other chemicals for cleaning screens and preparing garments. The specific chemicals used depend on the type of ink – plastisol, water-based, discharge or solvent-based. These inks each have their own requirements for emulsion, screen conditioners, and garment pretreatments to achieve quality results.

By properly handling and disposing of these chemicals according to the product instructions, screen printers can work safely and sustainably. Choosing eco-friendly inks and chemicals whenever possible is an easy way for shops to reduce their environmental impact. With some care and consideration of human and environmental health, screen printing can be a very responsible process.

What are the 6 basic types of screen printing

Screen printing is a popular printing technique used to transfer ink onto a surface, typically a t-shirt or other fabric. There are six major types of screen printing:

Paper Stencil:

The original screen printing method using hand-cut paper stencils. Labor-intensive but still used by some artists.

Photo Emulsion:

A light-sensitive emulsion is applied to a screen and exposed to UV light through a film positive, hardening the emulsion and creating an open area for ink to pass through. Most common for commercial screen printing.

Vinyl Stencil:

Pre-cut vinyl stencils are applied to a screen, allowing ink to pass through the open areas. Easy to use but limited in detail. Good for simple designs with solid colors.

Direct Emulsion:

A light-sensitive emulsion is directly applied to a screen and exposed to UV light, hardening the open areas. Requires a film positive and exposure unit but eliminates the need for stencils.

Digital Direct Emulsion:

Inkjet printers are used to print the design onto emulsion-coated screens. Eliminates the need for film positives but requires special inkjet emulsion and printers. Mostly used by smaller print shops.

Computer to Screen:

Designs are printed directly onto screens using special inkjet printers, eliminating the need for emulsions and exposure. Limited to certain inks and mesh counts but a fast, efficient process for high-volume printing.

The specific technique used depends on factors like the complexity of the design, number of prints needed, and equipment/resources available. With some basic equipment and knowledge, screen printing can be done on a small scale at home or large scale for commercial production.

Conclusion

So there you have it, an overview of the screen printing process and the different types of screen printing along with the materials needed. Screen printing is a versatile and creative process that allows you to print custom designs on all sorts of surfaces. Whether you want to print t-shirts for your sports team, create artistic prints to sell, or promote your business with custom branded materials, screen printing has you covered. The options are endless. Now that you understand the basics, you can get started creating your own custom prints. Have fun with it and be sure to share photos of your screen printed creations! We’d love to see what you come up with.