Screen printing offers great flexibility in design placement, allowing for highly customizable outcomes. This versatility stems from the manual nature of the screen printing process, which allows the screen printing technician to exercise precise control over design placement. Unlike machine-based printing methods, where design placement is constrained by the equipment's capabilities, screen printing enables intricate designs to flow seamlessly around corners, follow curved edges with precision, and even be printed at unconventional angles. This manual control allows for the creation of continuous designs that seamlessly integrate with the contours and dimensions of the substrate.
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The versatility of screen printing extends far beyond traditional printing mediums- it offers an expansive range of materials on which designs can be printed on, from the classic canvas of paper and fabric to more unconventional surfaces like wood, metal, plastic, glass, and more. This adaptability allows for a greater range of creative possibilities and experimentation for artists, designers, and creators. Furthermore, it allows for printing on textured materials, curved surfaces, and uniquely shaped objects. This degree of customization is especially beneficial for projects emphasizing artistry and utilizing unique substrates.
While screen printing may entail higher initial setup fees compared to more modern methods like digital printing, its cost-effectiveness for bulk printing becomes increasingly apparent. As order quantities increase, the price per printed unit decreases significantly, making screen printing an economical choice for large-scale print projects. This is attributed to the manual nature of screen printing- creating and utilizing multiple stencils for a single design. Consequently, significant discounts are often offered for large quantities, as the same stencils can be utilized across the entire batch. However, it's essential to note that the overall cost is still heavily influenced by factors such as the complexity of the print and the need for adjustments to the artwork, both of which impact the number of stencils required in the process.
The cost of screen printing is directly impacted by the number of colors involved in the design. Since each color typically requires a separate screen to be created, it adds to the initial set up time and resources used. As a result, screen printing becomes less cost-effective as the number of colors in a design increases. This stands in contrast to digital printing, where multiple colors can be printed simultaneously, making it a more budget-friendly option, particularly for intricate and colorful designs.
The setup process required for screen printing is labor-intensive and time-consuming, contributing to the high fixed costs associated with this method. As a result, screen printing tends to be less economically viable for short print runs. If the objective is to produce a limited quantity of prints or on-demand prints, alternative printing methods like digital printing offer a more cost-effective solution, as the setup process is minimal and straightforward by comparison.
While screen printing excels at producing bold and simple designs, it may struggle to capture the intricate details or complex gradients found in certain artwork. The process relies on screens with limited resolution, posing difficulties in accurately reproducing fine lines or tiny text. Moreover, aligning multiple screens for multi-colored designs can result in slight misalignments and blurring of fine details. For highly detailed designs, superior results are achievable through digital printing or sublimation printing, which allow for more precise reproduction of intricate artwork.
Given that screen printing involves multiple manual steps such as screen preparation, color separation, ink mixing, alignment, and printing, it inherently operates at a slower pace compared to modern printing techniques. For instance, each color in a design requires its own screen and individual pass, therefore extending the production time for multi-color and intricate designs. Additionally, the drying time for each layer of ink can further contribute to the overall production duration. These combined factors significantly impact the time required to complete a project compared to more automated modern methods such as digital printing. When dealing with time-sensitive projects, it is crucial to consider these factors when selecting a screen printing partner to ensure they can meet your project timeline.
Here's a recap:
Screen printing is a versatile and appealing option for producing high-quality, clean, professional prints as it offers a range of advantages such as its vibrant output, high opacity, durability, and its flexibility in design placement and material options. Its cost-effectiveness for large-scale projects further enhances its appeal. However, it's crucial to acknowledge the limitations of screen printing, including the higher costs for multi-color prints, reduced feasibility for short print runs, and challenges with highly complex designs or extreme detail. Additionally, the slower turnaround time compared to digital printing must be considered, especially for time-sensitive projects. By carefully evaluating these factors, you can make informed decisions about whether screen printing aligns with your specific printing needs. It is always best to consult with experienced industry professionals as they can offer valuable insights for your specific project requirements, quality expectations, and budget constraints.
BluEdge has been in business for over 125 years and a trusted industry partner for providing high quality, commercial screen printing services. We operate in our 65,000 sq. ft. production facility, utilizing innovative equipment and technology and the finest materials to ensure that every print meets our clients' highest standards. Our screen-printing technicians have decades of experience in PMS color matching, quality control, and executing both simple and complex designs at on-demand speed.
BluEdge isn't just another printing service, we're about building trust and lasting relationships with everyone we work with. We pride ourselves on our open communication, transparency, and support our clients' beyond their needs to guarantee satisfaction. Whether you’re a small business or a large corporation, have a big or small project, we bring the same urgency and craftsmanship to the table every time.
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BluEdge is a national provider of comprehensive Business Technology Solutions and Experiential Marketing Services. We’ve been supporting our clients since our establishment in . BluEdge has been family-owned and operated for over 125 years and is proud to be a certified Woman Business Enterprise.
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So many screen printing shops have a hard time working with water based inks.
It’s not that water based inks are difficult. It’s that most shops don’t know where to start, since they’ve used plastisol ink for so long and may have learned to print with it. Spending a little time to do some R&D on your screen printing inks can yield huge returns.
Plastisol ink is just polyvinyl chloride (PVC, the same stuff common pipes are made of) and liquid plastic.
It’s the most common ink you’ll see in any screen printing shop. Why? Because it’s cheap, readily available, durable, and generally easy to work with.
Leave it on your screens with no problem. Leave it on a shelf forever and use it years later. Make sure it’s cured correctly, and it can last a hundred washes.
Sounds great, right? It mostly is.
Why would screen printers want to invest time and energy into learning water based inks when plastisol is so easy, cheap, and permanent?
Because water based inks have some real advantages that make them appealing to customers and printers: they feel better, they’re better for the environment, and they unlock some powerful printing capabilities in your shop (plus they just look amazing).
This is a simple truth: a good water based print feels better than a plastisol print.
While you can make a soft plastisol print, a water based print can often be nearly as soft as the t-shirt itself.
This means customers that love soft prints will almost always want water based inks.
Compared to plastisol, some water based inks use fewer toxins and petroleum products.
While this isn’t always the case (and can be a common misconception), water based inks are generally considered better for the environment among industry experts.
The reasons include water based inks being made with fewer volatile and toxic chemicals, requiring less of a carbon footprint to produce, and producing less waste that goes to the drain compared to plastisol.
While plastisol tends to last for a hundred washes and then begin to fade, crinkle, and even chip off the garment (think of a really old t-shirt you might have) – water based inks can actually last much longer.
This is because water based inks can actually become part of the garment. Plastisol simply sits on top of the garment! Water based inks (since they’re water based) leave behind pigments.
These pigments can become part of the fabric itself and last as long as the garment lasts.
While you can achieve high detail prints with plastisol, water based inks can be made so thin that they’re able to be used on extremely high mesh counts.
This means shops like Night Owls Print and Printed Threads, which print high-detail water based art, can achieve photorealistic results and microscopic details.
If you’ve ever worn a t-shirt with a large plastisol print, you know that plastisol ink simply doesn’t “breathe”.
Most water based inks don’t feel like this. Water based inks typically able to allow air to pass through, since the pigments are embedded within the fibers of the garment.
While Pantone matching water based inks was a problem in the past, it’s now something that highly technical shops can do effortlessly.
There’s some apprehension about water based inks: won’t they be less vibrant than plastisol? The answer to that question is no. Water based inks do not sacrifice quality or color.
Everyone in the industry likes to fight over which screen printing ink is best.
It’s really like asking which pizza is best. (It’s Pequod’s, though. I may have to watch my back for a while.)
The truth is very simple.
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The best water based ink fulfills two criteria:
If the ink comes from a supplier you trust and it works for you, then it’s good ink. Don’t worry about the other noise.
To find the inks you like, prioritize testing different inks. You can probably get samples from sales reps. Learn from the screen printing process and experiment with your techniques. Remain open to surprises and changes in your process – it’s worth the investment in time and energy.
Water based inks are literally any ink that has water as its key component.
That tends to throw people off!
Traditional water based and discharge inks don’t sit on top of the shirt like plastisol does. Instead, the actual fibers of the shirt are altered. This makes for a long-lasting print that’s as soft as the shirt is. Not all water based inks work this way, though…acrylic inks are a notable exception.
So here’s a breakdown of the different water based inks.
With a runny, almost liquid consistency, water based ink alters the garment’s fibers. It has a tremendously soft hand feel. Because of the high water content of the ink, it must stay wet during printing.
A fluid, but slightly more viscous, consistency than traditional water based ink. Discharge inks are a powerful tool. They work by using an activator to bleach out the existing colors on the shirt. This means you can reliably print vibrant colors even on dark garments by using discharge inks as an underbase layer.
With acrylic particles added, this type of water based ink has a thicker, plastisol-like consistency. It does not actually alter the fibers of the garment. Acrylic inks come from the consumer need for a plastisol-like water based ink. It doesn’t need quite as careful management on the screen as other water based inks.
Acrylic inks are becoming more popular thanks to the growth of digital hybrid printing (also known as “the giant new machines that cost as much as a small house”). Lots of digital printing machines print on top of a tradition screen printed underbase – and most require some type of acrylic ink.
Plastisol is incredibly easy to use. It won’t dry up sitting on a screen and will never puddle. So why should you switch to water based ink?
This is simply the most common issue with water based inks, particularly with top-coat water based inks like acrylic ink.
In the fine art world, the simplest solution is to add a retarder: glycerine would be added to ink to keep it from drying.
There are three solutions for slowing down the drying process with your water based inks:
Check with your ink manufacturer to see what kind of retarder they suggest.
A water based ink retarder slows the drying time and increases the “open time”. Some manufacturers offer multiple additives that alter how the ink behaves. In my experience, using the recommended retarder combined with a lubricant is the best way to keep ink flowing and slow the drying process in the screen.
I bet you didn’t think you’d need a reptile fogger.
Here’s a brilliant hack to keep your water based inks from drying up in the screen:
Use a reptile fogger to keep your ink wet!
These cost about $50 when they’re new, and you get a 1 liter system that sprays a cool mist. It’s attached to a hose, so you can move the hose and clip it wherever you’d like to keep the fog directed at your screen.
Here’s an example:
Be sure to use distilled water in your fogger to keep contaminants out!
All jokes aside, throughout the years I’ve learned that coating your screens with the ink manufacturer’s recommended lubricant is critical.
Before any water based ink goes on your screen, apply lubricant with a clean cloth and rub it liberally into the open areas of your image. Use a little water to help spread the lubricant completely through the mesh, then wipe it clean.
By penetrating the entire mesh with lubricant, you slow down drying and make printing much smoother.
This is the other big problem shops run into when they start printing with water based ink: their screens start breaking down. Water is the universal solvent, after all.
Emulsion formulation is key to keeping your screens from breaking down. Emulsions have different solid content levels, different levels of durability when exposed to different inks, different exposure properties and so on. So how do you choose?
Virtually every supplier for garment decorators has a good emulsion that you can use. You may have to alter your emulsions to get the toughness you’ll need.
When in doubt, go with Diazo for the best durability when screen printing with water based ink. Ideally, you mix powder Diazo blended with water into the emulsion. This can create a powerful emulsion that is more durable than standard photopolymer emulsions that are ready for use out of the bucket.
Proper exposure leads to optimum cross-linking. Cross-linking is when the semi-solids in your emulsion become a solid through reaction with UV light. Take the time and invest in getting exposure 100% right.
Always post expose.
Here, I’m going to say it louder: ALWAYS POST EXPOSE!
This is a super simple step that so many shops overlook or think isn’t necessary.
After you’ve exposed your screen and it’s dried off, take your screen and expose it to more light. Turn off your exposure unit’s vacuum function and expose the screen ink-side down (opposite of how you normally expose screens). You can even just expose it to sunlight for a minute or so.
The point is to further harden the ink-side of the screen. This is a very easy way to improve the durability of your screens.
Water based inks are an opportunity to offer your customers the longest-lasting and softest custom shirt possible. It’s a screen printing technique that adds value and impresses clients.
Too many screen printing businesses are afraid to experiment with new techniques – but water based inks are a fantastic opportunity to do something new.
Now that you know where to start, and are armed with some practical tips, go find out how you can utilize water based inks in your shop.
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