How Screen Printing Works (And Why It’s So Popular)

Table of Contents

1. What’s screen printing?
2. Why screen printing over other methods?
3. List of equipment
4. The step-by-step process of how screen printing works
5. Screen printing vs. heat transfer printing vs. digital printing
6. Screen printing benefits
7. Start your journey with Imprint Engine

What’s Screen Printing? A Quick Overview

Screen printing is a method of transferring designs onto surfaces using a mesh screen, ink, and a squeegee. While it’s most commonly used to make t-shirts and other fabric goods, it can print on almost any kind of surface, like paper, metal, glass, wood, plastic, or even leather. Screen printing can be done manually or by using automated machines like the ones we have in our production line.

Why Opt for Screen Printing Over Other Methods?

Its compatibility with many surfaces is one reason why screen printing is one of the most popular decoration methods, but it’s certainly not the only reason. Here are a few more advantages that make screen printing so prominent. 

Vibrant colors

Its wide array of color options is the biggest factor that sets screen printing apart from other decoration methods. Not only is the color selection seemingly endless, the colors themselves look bold against any surface, which other techniques struggle to achieve. The most vibrant colors stand out on even the darkest fabrics because the ink sits on top of the surface in layers. 

Unique texture

Because the ink is able to layer on top of itself, it gives the print a unique, tangible texture that makes the product feel higher quality. The ink can also be coated to prevent scratches or fading from moisture or UV rays.

Efficient for High-Volume Production

Screen printing is one of the fastest techniques, making it both cost- and time-efficient for high-volume orders. Once everything is set up, the decoration process moves quickly since the same stencil can be used over and over again when producing bulk orders.

Screen Printing Equipment

Like anything, a high-quality outcome requires a high-quality process. And that includes good equipment! In order to achieve an attractive end product, your screen printer needs the best tools for the job. Let’s get into what comprises a screen printer and the purpose each piece serves.

Screen Printing Press

You can screen print without a screen printing press, but the press allows you to print items faster and easier. There are three kinds: manual, which is hand-operated and labor-intensive, semi-automatic, which is partly automated but still needs some human effort, and automatic, which is fully automatic and require minimal effort from you.

Ink

The ink pushes through a screen onto the desired surface to imprint your design. But there is much more to consider than just color when selecting your ink. Special inks can add special effects to your products, such as puff inks for a raised design, glitter or textured inks for flair, or washable inks for a more durable design on clothing items. 

Silk Screen

Fine mesh fabric stretches over a frame to create the silk screen. The mesh used to be made of silk, but modern screens are made with polyester which achieves the same outcome at a lower price. You can choose a higher or lower thread count to best suit the texture and design being printed. A high thread count is better for detailed designs while a low thread count works well for bold, simple prints.

Squeegee

The squeegee is a rubber blade attached to a long handle made of wood, metal, or plastic. This is used to push the ink through the mesh screen to imprint your design. Firm rubber blades are meant for detailed prints and softer blades are for simpler designs or fabric printing.

Washing Station

After the print is complete, screens must be washed to remove every last bit of emulsion so they can be used again for fresh prints. This process takes place at the washing station, where tubs of special cleaning solution or a sink with a power hose can get the job done.

The Step-by-Step Process of How Screen Printing Works

Let’s get into how screen printing works, step by step.

Create Design

Once you’ve poured your creative energy into a finished design, you will print it onto a transparent acetate film. This film acts as the template for the stencil.

Prepare the Screen

Next, you select a mesh screen with a high or low thread count depending on how detailed or broad your design is. The screen is then stretched over a frame and coated with a light-reactive emulsion layer.

Expose Emulsion

Exposing the emulsion includes placing the acetate film from step one onto the coated screen and exposing it to bright light. This step hardens the emulsion in areas not covered by the design. If your design includes multiple colors, a separate screen must be used for each color.

Wash Off Emulsion, Create Stencil

When you rinse off the unhardened emulsion, you’re left with your design imprint on the screen. Then you dry the screen and touch up any areas as needed. Now your stencil is ready to be used! 

Prepare Item for Print

Place the screen on the printing press and lay the garment or item flat on the printing board beneath the screen. Automatic rotary printers are often used for efficient, multi-color designs.

Ink Press and Squeegee

In this step, your design comes to life. Lower the screen onto your garment or item, add ink to the top, and use the squeegee to press it through the stencil. For multiple items, repeat the process after placing each new piece on the printing board. Once finished, clean the screen so you can reuse the mesh for future designs.

Heat, Cure, Done

Run the printed project through a dryer to cure the ink and lock in durability. Check the final product, wash away any residue, and prepare for delivery! 

Screen Printing vs. Heat Transfer Printing vs. Digital Printing: What’s the Difference?

When looking into decoration methods, heat transfer printing and digital printing are other common techniques you’ll find. Here’s a brief overview of how each works: Digital printing uses a fabric printer to transfer an image directly onto a garment, sort of like the paper printer you might have at home. It requires less set-up than screen printing, which makes it more cost-effective, but it lacks the capabilities for texturized effects or a broad range of vibrant, custom colors. Heat transfer is a technique that uses heat to press a design into fabric. Both heat transfer and digital printing are easy and cost-effective for small batches, but quality and durability are what set screen printing apart from other techniques. 

Read about how we transfer digital images to printed merchandise without losing quality or color vibrance.

The Advantages of Screen Printing

We believe there are plus sides to any decoration method. What might be right technique for your t-shirts might not be the best option for jackets or duffel bags. Our in-house production facility has every tool you can think of to bring your merch vision to life. Read our list of pros and cons for every decoration method available.

As you weigh your options, consider the following benefits of screen printing. 

Durability

Compared to other print methods, screen printing is able to lay heavy ink coverage that bonds strongly to your materials, giving you a much more durable design. Screen printing also allows you to add special coatings to prevent scratches, fading, or warping from UV rays, chemicals, or wash cycles.

Choice of Colors & Ink Vibrancy

Screen printing can individually layer colors to preserve each color’s intended brilliancy. This is simply impossible to achieve with other techniques.

Cost-Effectiveness

Screen printing is great for large quantities, unlike other print methods that are most cost-effective for small batches. Once set-up is complete, you’re off to the races and can produce automated, high-quality merch! In the long run, this saves you money on high-volume orders because the more you print, the cheaper you spend per unit.

Fast & Efficient

Again, screen printing is an amazing option for high volume orders because the same design can be printed over and over again on a fast-moving production line. Even when done manually, screen printing is one of the quickest print methods available once you’ve got your process down.

Get High-Quality, Long-Lasting Company Merchandise with Imprint Engine

Now that you know how screen printing works, you can understand why it is one of the most popular decoration methods. It’s fast and efficient for large quantities and results in durable, vibrant, high-quality merchandise. We’ve created millions of units using our automated screen printing process, and we’re here to help you bring your ideas to life.