If you’re new to the sublimation industry, you’ve probably heard about the term “screen printing” at least once.
Screen printing technology allows you to create printed products by printing graphics on items using thick layers of ink. The design is transferred through a mesh screen onto a substrate.
This method is a classic, and it’s been used in the apparel industry along with other industries for decades. It was actually the only method to make graphic clothes for a few decades.
In this guide, we’ll let you in on everything about screen printing and how it works. So, let’s get started!
What Is Screen Printing?
Screen printing is a printing technique where a mesh is used to transfer ink (or dye) onto a substrate, except in areas made impermeable to the ink by a blocking stencil. A blade or squeegee is moved across the screen to fill the open mesh apertures with ink, and a reverse stroke then causes the screen to touch the substrate momentarily along a line of contact.
This causes the ink to wet the substrate and be pulled out of the mesh apertures as the screen springs back after the blade has passed. One color is printed at a time, so several screens can be used to produce a multi-colored image or design.
A stencil is formed by blocking off parts of the screen in the negative image of the design to be printed; that is, the open spaces are where the ink will appear on the substrate.
Before printing occurs, the frame and screen must undergo the pre-press process, in which an emulsion is ‘scooped’ across the mesh. Once this emulsion has dried, it is selectively exposed to ultra-violet light, through a film printed with the required design. This hardens the emulsion in the exposed areas but leaves the unexposed parts soft.
Once the screen is exposed, it is washed with a water-based solvent to remove the unexposed emulsion. The screen is then ready to be used for printing.
To print, the screen is placed over the substrate, and the ink is applied to the back of the screen with a squeegee. The ink is forced through the open areas of the screen and onto the substrate. The excess ink is then wiped away, and the process is repeated for each needed color.
Screen printing is a versatile printing technique that can be used to print on a variety of substrates, including paper, fabric, metal, and plastic. It is also a relatively inexpensive printing technique, which makes it a popular choice for small businesses and entrepreneurs.
Here are some of the benefits of screen printing:
- It is a versatile printing technique that can be used on a variety of substrates.
- It is a relatively inexpensive printing technique.
- It can be used to print large quantities of items.
- It is a durable printing technique that can withstand wear and tear.
Here are some of the drawbacks of screen printing:
- It can be a time-consuming printing process.
- It can be a messy printing process.
- It can be a difficult printing process to learn.
Overall, screen printing is a versatile and affordable printing technique that can be used to print a variety of items. If you are looking for a printing technique that is durable, inexpensive, and versatile, then screen printing is a good option to consider.
How Does Screen Printing Work?
Screen printing is a versatile printing process that allows images to be printed onto various materials such as fabric, paper, glass, and more. It’s a technique that requires a stencil, or screen, for each color that makes up the design. The process might seem complex at first, but it can be broken down into the following steps:
1. Creating the Design:
First, you need to come up with a design that you want to print. This design is typically created using graphic design software, and the final image should be in a high resolution to maintain the quality of the print. Once your design is complete, it needs to be printed onto a transparent acetate film. The acetate film acts as a stencil or negative during the screen printing process.
2. Preparing the Screen:
A screen is made from a fine mesh, typically polyester or similar material, which is stretched over a frame. The frame can be made from various materials, such as wood or aluminum, and the mesh should be taut to ensure accuracy during the print process. Screens come in various mesh counts, which refer to how many threads of mesh there are crossing per square inch. The mesh count chosen will depend on the level of detail in your design and the viscosity of the ink you plan to use.
3. Coating and Exposing the Screen:
After the screen is prepared, it needs to be coated with a light-reactive emulsion. The emulsion is spread evenly onto the screen with an emulsion scoop coater. This creates a thin layer that will be sensitive to light exposure. Once coated, the screen must be left to dry in a dark room or cabinet, as the emulsion is light-sensitive.
4. Exposing the Emulsion:
After the emulsion has dried, it’s time to expose it. The design of the acetate film is placed on the screen, and then the screen is exposed to a strong source of light. This can be done using a special exposure unit, or sometimes even the sun can be used for this purpose. The light hardens the emulsion not covered by the design on the acetate, creating a stencil. The areas of the screen covered by the design remain unhardened because they’re shielded from the light.
5. Washing Out the Screen:
After exposure, the screen is washed out with a gentle spray of water. The water washes away the areas of emulsion that were not exposed to light (those that were shielded by the design). This leaves a clear pathway in the shape of your design for the ink to pass through.
6. Setting Up for Printing:
Once the stencil is ready, the screen is placed on a screen printing press. The material to be printed on (such as a t-shirt, poster, etc.) is placed under the screen on the press. The screen must be properly aligned or “registered” to ensure the design prints in the correct location.
7. Inking and Printing:
Next, ink is placed on one end of the screen. Using a squeegee, the ink is then pulled across the screen. This forces the ink through the mesh and onto the material beneath. The ink only passes through the areas of the screen where the stencil is present (where the emulsion was washed out), hence replicating the design onto the material.
8. Curing the Print:
After printing, the ink needs to be cured. This is often done by passing the material through a conveyor dryer, which subjects the print to a specific amount of heat for a certain amount of time. This process sets the ink and makes the design permanent, ensuring it won’t wash off or fade.
9. Cleaning and Reclaiming the Screen:
After the print run, the screen is cleaned of any excess ink with a suitable cleaning solution. To reclaim the screen for future use, an emulsion remover is applied to dissolve the remaining emulsion. The screen is then rinsed and dried, ready for its next design.
1O. Repeat for Multi-Colored Designs:
If your design involves multiple colors, you will need a separate screen for each color. Each color layer must be printed and dried separately before the next layer is applied. This process is repeated until the final design is completed.
Keep in mind, that screen printing requires practice and patience, but it can also be a fun and rewarding process. It allows for a lot of creativity and is an excellent way to create custom designs.
A Guide to Screen Printing Equipment
Starting a screen printing business or setting up a screen printing studio requires various equipment. Here’s a guide to the basic equipment you will need:
1. Screens: The most crucial part of screen printing is the screens themselves. You will need a screen for each color in your design. Screens come in different mesh counts which can be selected based on the detail of your design and the thickness of the ink you’re using.
2. Frames: Screens need to be tightly stretched across a frame. Frames can be made of wood or metal and should be durable and warp-resistant.
3. Squeegees: Squeegees are used to push ink through the screen onto your print surface. They come in different hardness levels (durometers), lengths, and shapes. The size and hardness of your squeegee will depend on the detail of your design and the print surface.
4. Inks: There are a variety of inks available for screen printing, such as water-based inks, plastisol inks, discharge inks, and more. The choice of ink will depend on your design, your print surface, and the effect you want to achieve.
5. Emulsion: Photo emulsion is used to create the stencil on your screen. You will also need a scoop coater, a tool that helps apply the emulsion onto the screen in a smooth, even layer.
6. Light Source/Exposure Unit: You need a strong light source to expose the emulsion and create your stencil. This can be as simple as the sun, or as sophisticated as a specialized exposure unit which allows for better control and consistency.
7. Press: A screen printing press holds your screens in place and allows for accurate registration of your design. Presses can be manual or automatic and come in a variety of sizes. Manual presses are less expensive and require more physical work, but are great for beginners or smaller operations. Automatic presses are more expensive, but they can greatly increase your efficiency and output.
8. Conveyor Dryer: After printing, your prints need to be cured, or dried. While you can use a simple heat gun or flash dryer for small operations, a conveyor dryer will ensure even curing and increase your efficiency for larger operations.
9. Washout Booth and Pressure Washer: These are used to clean your screens after printing and to wash out the unexposed emulsion when preparing your screens. A washout booth helps contain the mess, while a pressure washer ensures a thorough clean.
10. Darkroom/Screen Drying Cabinet: A light-safe environment is needed for drying your screens once they’ve been coated with photo emulsion. For small setups, this could be a closet or bathroom with black-out curtains. For larger setups, a screen drying cabinet might be more appropriate.
11. Screen Printing Software: A design software to create artwork for screen printing. Adobe Illustrator or CorelDRAW are common choices.
12. Cleaning Supplies and Green Screen Printing Chemicals: You will need a variety of cleaning supplies, including emulsion remover, ink degrader, and haze remover, as well as scrub brushes and a power washer.
13. Heat Press (Optional): If you are printing on fabric, a heat press can be used for curing ink, especially for heat transfer designs, and gives a uniform and professional finish.
14. Screen Printing Registration System (Optional): A registration system allows you to line up your screens perfectly. This is extremely important when doing multi-color prints.
Keep in mind that the specific equipment you need may vary depending on what type of screen printing you’re doing, the size of your operation, and the materials you’re printing on. Start with the basics and invest in additional equipment as your needs and skills develop.
The History of Screen Printing
Screen printing is a printing technique where a mesh is used to transfer ink onto a substrate, except in areas made impermeable to the ink by a blocking stencil. A blade or squeegee is moved across the screen to fill the open mesh apertures with ink, and a reverse stroke then causes the screen to touch the substrate momentarily along a line of contact.
The history of screen printing is long and varied. The earliest known use of screen printing was in China during the Song Dynasty (960–1279 AD). At that time, screen printing was used to print textiles and other materials. The technique was later adopted by other Asian countries, such as Japan and Korea.
In the 17th century, screen printing was introduced to Europe. The first European screen printers were primarily used to print textiles and other materials. However, the technique was soon adapted to print other items, such as posters and signs.
In the 19th century, screen printing saw a resurgence in popularity. This was due in part to the invention of the rotary screen printing press. The rotary screen printing press made it possible to print large quantities of items quickly and efficiently. As a result, screen printing became a popular choice for businesses and organizations that needed to print large quantities of promotional materials.
In the 20th century, screen printing saw even more growth and popularity. This was due in part to the invention of new inks and solvents. These new inks and solvents made it possible to print on a wider variety of materials, including plastics and metals. As a result, screen printing became a popular choice for businesses and organizations that needed to print a variety of items.
Today, screen printing is still a popular printing technique. It is used to print a wide variety of items, including clothing, posters, signs, and more. Screen printing is a versatile and affordable printing technique that can be used to create high-quality prints on a variety of materials.
Here are some of the key events in the history of screen printing:
- 960–1279 AD: Screen printing was first used in China during the Song Dynasty.
- 17th century: Screen printing was introduced to Europe.
- 19th century: The rotary screen printing press was invented.
- 20th century: New inks and solvents are invented, making it possible to print on a wider variety of materials.
- Today: Screen printing is still a popular printing technique used to print a wide variety of items.
What is the Difference Between Screen Printing and Digital Printing?
Screen printing and digital printing, often referred to as Direct-to-Garment (DTG) printing, are two common methods of printing on materials like textiles, but they have distinct differences in terms of process, cost-effectiveness, and best use cases. Here’s a breakdown:
Screen Printing
Screen printing is a traditional method that involves creating a stencil (or a series of stencils for multicolor designs) and applying layers of ink to the printing surface one at a time. The ink is pushed through a woven mesh stencil onto the print surface.
Advantages of Screen Printing:
- Durability and Quality: Screen prints can last for a long time and resist wear and tear. The colors are vibrant, and the ink adheres well, especially on the fabric.
- Cost-Effective for Large Batches: Once the screens are created, many prints can be made quickly, so it’s cost-effective for large orders.
- Versatility: It can be done on various surfaces, including textiles, ceramics, wood, paper, glass, and metal.
Disadvantages of Screen Printing:
- Not Economical for Multiple Colors and Small Batches: If a design has many colors, a separate screen needs to be made for each color, which can be costly and time-consuming.
- Less Detail: Fine details and photographic prints may not come out as clearly due to the nature of the technique.
Digital Printing (DTG)
Digital printing involves translating digital images directly from a computer onto the material to be printed using a specialized printer, similar to how your desktop inkjet printer works. It’s like printing directly onto the material.
Advantages of Digital Printing:
- Detail: Digital printing can capture intricate details and a wide array of colors. It’s great for designs that have a lot of detail or a wide variety of colors.
- Cost-Effective for Small Batches and Multicolored Designs: Unlike screen printing, digital printing doesn’t require any setup, so it’s more cost-effective for small orders. Also, printing a design with many colors doesn’t cost any extra.
- Speed: Because it doesn’t require a drying time, digitally printed items can be produced quickly.
Disadvantages of Digital Printing:
- Not as Durable: The print’s longevity might not be as long as screen-printed items, particularly on textiles that are washed frequently.
- Limited to Flat Surfaces: DTG printers require a flat surface to print on, limiting the types of products and materials on which you can print.
When to Use Which
- Screen Printing: Best for large orders (of the same design) and designs with limited colors to keep the cost down. Ideal if durability is a major concern.
- Digital Printing: Best for small orders, designs with high amounts of detail or wide color variety, or personalized printing with variations in design. It’s also a good choice for rapid prototyping or fast turnarounds.
Both methods have their own advantages and are suited to different situations. The best method depends on the specifics of the project, such as the complexity of the design, the number of items to be printed, the type of fabric or material, and the available budget and timeframe.
What’s the Difference Between Silk Screen Printing and Heat Transfer?
Both screen printing and heat transfer are printing techniques that can be used to create custom designs on a variety of materials. However, there are some key differences between the two processes.
Screen printing is a process that uses a mesh screen to transfer ink onto a substrate. The mesh screen is coated with a light-sensitive emulsion, which is then exposed to ultraviolet light. The areas of the screen that are not exposed to light harden, while the areas that are exposed to light remain soft. The ink is then applied to the back of the screen and forced through the open areas of the screen onto the substrate. This process can be used to print a variety of designs, including text, images, and logos.
Heat transfer is a process that uses heat to transfer a design from a transfer sheet onto a substrate. The transfer sheet is coated with a heat-activated adhesive, which melts when exposed to heat. The transfer sheet is then placed on the substrate and heat is applied using a heat press or an iron. The heat melts the adhesive, which bonds the design to the substrate. This process can be used to print a variety of designs, including text, images, and logos.
Here are some of the key differences between screen printing and heat transfer:
- Process: Screen printing is a more complex process than heat transfer. It requires the use of a screen and a light-sensitive emulsion, which can be time-consuming and expensive to set up. Heat transfer, on the other hand, is a simpler process that requires only a heat press or an iron.
- Materials: Screen printing can be used to print on a variety of materials, including fabric, paper, and metal. Heat transfer, on the other hand, is typically used to print on fabric and other heat-resistant materials.
- Durability: Screen-printed designs are typically more durable than heat transfer designs. This is because the ink is actually embedded in the fabric or material, rather than simply being applied to the surface. Heat transfer designs, on the other hand, can be easily peeled off or damaged.
- Cost: Screen printing is typically more expensive than heat transfer. This is because of the cost of the screen and the light-sensitive emulsion. Heat transfer, on the other hand, is a more cost-effective option.
- Quantity: Screen printing is typically used for larger quantities of prints, while heat transfer is typically used for smaller quantities of prints. This is because screen printing is a more efficient process for printing large quantities of prints. Heat transfer, on the other hand, is a more cost-effective option for printing smaller quantities of prints.
Ultimately, the best printing technique for you will depend on your specific needs and budget. If you need to print a large number of prints, screen printing is a good option. If you need to print a small number of prints, heat transfer is a good option. If you are on a budget, heat transfer is also a good option.
See also: The 7 Best Screen Printing Machines
Is Screen Printing Cheaper Than Digital Printing?
Screen printing is more cost-friendly than digital printing, especially when it comes to bulk orders. However, for small quantities, digital printing would be cheaper.
This is because the majority of the costs of screen printing lie in developing the setup that includes the mesh and the stencil. Once it’s created, the following costs will only be the price of the ink.
So, it doesn’t make sense to go this route if you only need a few items.
Frequently Asked Question
What is screen printing and how does it work?
Screen printing is a printing technique where a mesh screen is used to transfer ink onto a substrate, except in areas made impermeable to the ink by a blocking stencil. The process involves creating a stencil on a mesh screen, then pushing ink through the screen onto the printing surface.
What are the pros and cons of screen printing?
Pros:
Screen printing can be used to print on a variety of materials, including fabric, paper, and metal.
Screen printing can be used to print large quantities of items quickly and efficiently.
Screen-printed designs are typically durable and long-lasting.
Cons:
Screen printing can be a time-consuming and expensive process.
Screen printing requires specialized equipment and materials.
Screen printing can be difficult to learn and master.
Why would you use screen printing?
Screen printing is commonly used when you need to produce a large number of items with the same design. It’s also ideal when you need a durable and vibrant print, such as on apparel or promotional items.
What is better screen printing or vinyl?
The choice between screen printing and vinyl depends on your specific needs. Screen printing is better for larger orders and for designs that require a high level of vibrancy. Vinyl is typically better for small orders, intricate designs, and when you need a print that stands up to heavy washing.
What are 4 disadvantages of screenprinting?
Not cost-effective for small quantities.
Can be costly and time-consuming for multicolor designs.
Requires a significant setup process.
Not ideal for highly detailed or photographic designs.
Can you do screen printing at home?
Yes, you can do screen printing at home. However, it requires some investment in equipment and supplies. You would need items like screens, a squeegee, ink, and emulsion. You would also need to set up a clean and light-safe area for developing your screens. It’s a process that requires practice, but it can be done.
Final Words
So there you have it, screen printing serves as a versatile and robust method for creating vibrant, durable prints. Its unique ability to create custom colors offers unparalleled creativity, and its efficiency in handling large print runs is unrivaled.
However, like any technique, it comes with its challenges. The setup required for each print run makes it less feasible for small quantities. Additionally, the one-color-at-a-time printing process may lead to alignment challenges and potential color bleeding, particularly for designs featuring multiple colors. Understanding these nuances will allow for more informed decision-making in your printing endeavors.
Enjoy your prints!
