Screen Printing Technology Hand Book Pdf

[Idara Viengxay]

Whilescreen printing can be manual - especially used when there are only small print runs required - it is very often automated, using advanced inks and materials in combination with computer technology to mass print. One of the biggest advantages of screen printing is that it can print on almost any kind of surface, be it fabric, paper, glass, wood, card, plastic or leather. In this article, we will discuss the screen printing process, its uses, types, and benefits.

Screen printing, also known as silk screening or silkscreen printing, is the process of transferring a stencilled design onto a surface using a mesh screen, ink, and a squeegee (a rubber blade). The basic process of screen printing involves creating a stencil on a mesh screen and then pushing the ink to create and imprint the design on the below surface. The most common surface used in screen printing is paper and fabric, but metal, wood, and plastic can also be used. It is a very popular technique because of many reasons, but the most compelling reason is the vast choice of colours that can be used.

Screen printing can be done by hand or using a machine but the basic process is always the same. The differences can be of the type of ink used, its rendered effect and the printed surface. Below is the screen printing process step by step:

The first step in the process of screen printing is to create the design. Once a design has been decided upon, it is printed onto a transparent acetate film, which will then be used to create the screen or stencil.

When the design is all set to go, it is time to select the screen and mesh count. Mesh count is the total number of fibres in one square inch. Which mesh count you need will depend on the design being printed:

The transparent acetate film is placed on the emulsion-coated mesh screen carefully under a bright light which causes the emulsion to harden and develop. It must be noted that when multiple colours are involved in the design, separate screens must be used for different colours.

Exposing the screen for a specific time will harden the uncovered areas of the screen, and the remaining unhardened emulsion, if any, will be rinsed away to leave a clear imprint on the screen. The screen is then dried, and if there are any touch-ups required, it will be done by the printer to make the imprint as close to the original design as possible. Now, the stencil is ready to be used.

In this step, the printed design will come to life. The screen is lowered down to the printing board. The desired colour ink is added to the top of the screen. A squeegee will evenly distribute the ink along the length of the screen. The ink presses through the open areas of the stencil and transfers on the underlying silk, consequently printing the design on the product.

The most common screen printing technique is spot colour screen printing. Spot colour screen printing uses the ink's stock colour by printing it through the stencil of the mesh. This technique produces a vibrant solid spot of colour. It is much simpler to use as compared to other screen printing methods. It can be an excellent option for printing on t-shirts, jackets, and hoodies, for example.

In halftone printing, single colours in gradients are printed. The entire process uses a single colour of ink, and this colour gets half-toned, resulting in a different shade when looked at from a distance. This technique is best used to obtain the multi-colour printing look without actually doing it. In addition, it is a cost-effective method since only one colour of ink is used.

Grayscale printing is an excellent method of printing full-colour images as one colour grayscales or halftones. The print will look more detailed if the halftone has more dots. It is not a black and white technique; instead, it pulls out the CMY or RGB or colour scales only but in shades of grey. Grayscale printing is one of the most cost-effective screen printing techniques, often used for printing black and white designs onto fabrics.

Duotone printing uses the combination of two halftones for printing the same image with two colours. First, a black halftone is printed with black ink, and then a second halftone is printed with colour ink. This technique is similar to sepia-toned print in photography. It provides a sophisticated and artsy effect.

The simulated printing process combines the four-colour printing process with spot colour printing. Since this technique is useful for both lighter and darker shades, it is versatile and popular with people looking to produce photorealistic print detail.

One of the main advantages of screen printing is its versatility. It can be used on any type of fabric, plastic, wood, glass or even metal. Plus, multiple colours can be used. There is almost endless design freedom when using screen printing.

Compared to other printing methods, screen printing can apply a heavy ink coverage, resulting in a durable design. Additionally, certain coatings and additives can make the ink resistant to UV rays, scratches, moisture and chemicals, allowing screen-printed products to be used outdoors and in harsh environments without fading.

The vibrant and bolder colours produced by screen printing is quite tricky to replicate with other techniques. For multiple colour designs, separate layers are used, which allows each colour to preserve its actual brilliancy.

Screen printing is a cost-effective method in the longer run. Once the set-up is done, it is relatively quick and easy to print items at high volumes. So, it's safe to say the more you print, the cheaper the unit cost becomes.

Screen printing is more versatile than other printing techniques as it can add a design to materials of any shape, size and thickness. As a result, screen printing has found use in many different ways, including:

At Ynvisible, we design and manufacture ultra-low-cost smart displays at volume using roll-to-roll screen printing processes. Not only that, our displays have endless design freedom, so you can create exactly what you need from the outset. Explore our volume production capabilities here.

What sets Extreme Screen Prints apart is that we apply these techniques to each and every order we print! In this guide, we'll explore various methods and techniques for achieving a soft screen print, including different ink types, flash curing, and ironing techniques.

Additionally, the choice of screen mesh count is critical in determining ink deposit thickness. Higher mesh counts yield finer details and thinner ink deposits, contributing to a softer feel on the fabric. We can experiment with different mesh counts to strike the right balance between detail clarity and softness. When printing photorealistic images or simulated process designs, using a higher mesh count such as 225 and higher, is crucial to hold detail and to also make sure the amount of ink being used is appropriate for the coverage of the design.

Curing temperature and time also play vital roles in achieving a soft feel with plastisol ink. While proper curing is essential for ink durability and wash fastness, excessive heat can make the ink stiff and less soft. By carefully controlling the curing temperature and duration, we can ensure that the ink fully cures while retaining its soft and flexible properties.

Techniques like flash curing can be beneficial. Flash curing involves briefly curing the ink between color layers to prevent bleeding and improve registration. By strategically implementing flash curing at lower temperatures, we can minimize heat exposure and maintain the softness of the final print. It is important, however, to still keep in mind the total amount of flashes used as overcuring the ink can still be a concern.

In summary, plastisol ink shouldn't be dismissed based solely on its reputation for producing heavy and stiff prints. With the right techniques and adjustments, we primarily use plastisol ink to create soft and comfortable prints that rival those made with water-based or discharge inks. By understanding and controlling key variables like ink viscosity, mesh count, curing temperature, and flash curing, we fully leverage the versatility of plastisol ink to deliver high-quality prints with an exceptional soft feel.

One of the best advantages of water-based ink is the soft hand printing that it innately produces. The ink is absorbed into the fibers of the fabric during the curing process rather than sitting on top. This integration with the fabric creates a seamless and smooth feel, almost as if the print is part of the fabric itself. This is particularly desirable for garments where comfort is extra important, such as t-shirts and activewear.

Additionally, the versatility of water-based inks is worth highlighting. These inks are suitable for use on a wide variety of fabrics, including cotton, polyester, and blends, making them a versatile option for a range of applications. Additionally, they excel on lighter colored garments, producing vibrant and crisp prints that stand out. Moreover, water-based inks offer the flexibility to achieve various effects, from solid and bold colors to subtle and vintage-inspired looks. This adaptability allows us to cater to diverse design preferences and customer demands.

In terms of durability, water-based inks can hold their own when properly cured. Although they may not be as inherently durable as plastisol inks, water-based prints can withstand regular washing and wear, maintaining their vibrancy and integrity over time. This durability ensures that prints retain their softness and visual appeal even after repeated laundering, offering long-lasting satisfaction to customers.

However, it's essential to acknowledge that working with water-based inks presents its own set of challenges. These inks tend to dry out more quickly than plastisol inks, which can lead to issues such as screen clogging if not managed effectively. It is important to be mindful of factors such as ink consistency, screen mesh count, and curing temperature to achieve optimal results with water-based inks. Despite these challenges, mastering the intricacies of working with water-based inks can unlock their full potential and enable soft, vibrant prints that delight customers and elevate their products.

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