What is Screenprinting?
Screen printing or silk screening is a printing technique particularly suited for flat or relatively flat surfaces. The start of the process involves a fine mesh or screen that is tightly stretched around a rigid frame. The areas that are not to be printed are masked out on the screen using Emulsion. To create the print, the framed screen is positioned over the item to be printed along with a dollop of thick ink. A squeegee is then used to press the ink through small holes on the screen. The masked areas prevent ink from passing through, but the unmasked areas allow the ink to be imprinted on the material. The final step is to send the item on a conveyor belt through a dryer. This curing process ensures that the inks dry quickly so that they materials can be stacked or packaged. Properly cured inks will remain on the printed substrate even under harsh conditions.
If more colors are desired in the final design, the process is repeated with different screens. Therefore, a design that requires four different colors would require four different screens. The screens are usually placed on a rotary press which allows the different color prints to be properly aligned or registered with each other. Some screen-printers have fully automatic presses that do not require any manual labor other than set-up and loading/unloading.
There are a variety of ways that the screen can be masked. The most straightforward way is to apply masking fluid, called Emulsion, directly on the screen. This technique is suitable for simple one or two color graphics but is ineffective for more complex prints. For multicolor jobs, screen-printers often use photosensitive emulsions to create the masked areas. First, the design is created on a clear piece of plastic film. Meanwhile, a photosensitive coating is applied to the entire surface of the screen and then dried. The film is placed on the prepared screen and they are exposed to bright light. After a period of time, the exposed areas can be washed off the screen with water which makes the screen ready to print.
Screen printing is most commonly used for t-shirts, garments and other fabrics. Screen printing also used on all sorts of other substrates ranging from plastic to metal. Although small and intricate details can be captured, screen printing is ideally suited for bold and graphic designs.
When a screen-printer prints on darker items, a base print may be required to ensure that the colors maintain their vivacity. A base color (usually white) is applied wherever the final print is desired; it is then flash-cured and the subsequent colors are printed on top. This flash-curing technique adds another step to the process, but ensures brilliant prints on dark or even black materials.
The screen is tightly stretched around the frame which in this case is made out of wood; the red emulsion is dried on the screen and serves as the mask. The squeegee is nothing more than a strip of rigid rubber mounted in a wooden handle. To begin the screen printing process, the operator positions the screen directly on top the item to be printed. Next, ink is be applied to the area directly above the unmasked logo, and the squeegee is used to press the ink through to the substrate. As the operator firmly presses down with the squeegee, it is slid along the surface to ensure that ink penetrates through all areas of the unmasked logo. If additional colors are required, the process is repeated with additional screens. When finished, the screen is removed and the printed item is ready for curing.
Flock
This is the application of fine cotton fibers to specific areas of or portions of graphics on a garment.
This technique produces a raised surface that is three dimensional and very soft to the touch.
Flock can be applied to large or small areas in a wide range of colors.
Discharge
When a garment is screen printed, inks are applied to the surface of the garment in one or more colors in one or more layers. Sometimes, the layers of the ink may not provide the desired “feel” of the finished garment.
Discharge literally removes the dye from the garment instead of adding ink colors to the surface of the piece. The chemistry used to remove the dye can be tinted in order to provide the desired coloration and contrast of the graphic being applied to the garment’s surface.
Crack Enamel
These applications are used to achieve an aged look to the type and/or graphics applied to the garment.
In some cases, self cracking enamel is used to provide aging as the garment is worn and/or handled.
Crack enamels are generally applied when the degree of aging and/or distress is pre-determined and additional aging is not desired. These “looks” are used in many fashionable applications throughout the retail and merchandising communities.
Rock Base
The Rock Base printing technique is designed to give the garment a raised, firm but very dry and coarse hand feel.
This application is used with many contemporary and fashionable designs throughout many industries.
Hand Painted Look
Most inks can achieve a certain level of height or thickness when applied to the surface of a garment.
In order to achieve a true “hand painted” look and feel, our techs test a variety of processes and applications for each project that requires this desired effect.
This results in the achievement of the finest hand painted look and feel available domestically or internationally.
See Throughs
A popular technique combines the printing of the inside and/or the outside of a garment. In the example at left, the lighter text is printed on the inside and meant to be read from the outside thorugh the outer printing.
When the message or graphic is to be printed on the inside only (and read from the outside), our experienced techs must plan and execute it’s density and composition to ensure proper quality and legibility.
When the messages or graphics are to be printed on the inside and outside of the garment, our techs coordinate and balance additional factors to ensure the desired reproduction.
Hand Splatter
This technique combines screen printing and/or embroidery with an application of paint literally hand splattered on each garment.
The patterns are somewhat pre-determined but the net result is still an individual and unique look to each and every garment.
The splattering can take many forms, sizes and shapes depending on the tools and hand motions used to apply it.
Puff
This application provides a three dimensional raised feel to the inks on the surface of the garment.
It can be used to enhance graphics or type in multiple colors and depths.
Its unique look and feel is being utilized by retailers, resellers and ASI companies in a wide range of applications.
Salt Glitter
The Salt Glitter printing technique is designed to give the finished graphic a glitter look.
A wide range of colors and densities can be applied to most types of garments.
This is especially popular in retail environments, unique logo applications and fashionable designs.
Waterbase Paint
Today, many garments are being printed with waterbase inks to provide a softer feel to the finished piece while ensuring the visual integrity of multi-colored images and graphics.
Shatterbase
The Shatterbase printing look is very reminiscent of the older style T-shirts produced in the 1960’s and 1970’s. This “retro” look is popular with retailers throughout the world.
Heavy Vintage Plastisol
The Heavy Vintage Plastisol is designed to have a heavy ink deposit with a smooth hand feel when finished.
Foil
We customarily apply a wide range of foils to a variety of garments.
The foils are available in many different colors and finishes and can be applied in a conjunction with other media as well.
Heat Transfers
Perfect for applications, such as team jerseys where each image (number) needs to be different, or for specialty techniques, such as the application of rhinestones (at left).
Transfers can be applied to a variety of garments through heat and pressure methods.
Transfers can be combined with other media including screen printing, embroidery and more.
Faux Heat Transfers
Faux Heat Transfers are designed to give the finished image a variety of appearances.
The finish can be high gloss or a flat look, depending on the specific application.
The transfer is applied over a printed image in order to give the appearance of an actual heat transfer.