Screen Printing
How it works:
Design Preparation: The process begins with creating a digital design, this design is then transferred onto a transparent film, with each color separated into different layers.
Screen Preparation: A mesh screen is tightly stretched over a frame, washed and the degreased. Then the screen is coated on both sides with a light sensitive emulsion and left to dry.
Exposure: Each transparent film is placed on top of the coated screens and exposed to UV light. The light hardens the emulsion not covered by the design, creating a stencil on the screen corresponding to the design layers.
Washout: After exposure, each screen is washed with water. The unhardened emulsion washes away, leaving a clear stencil on the screen where the ink can pass through. Each screen Is then left to dry for a 3rd time.
Setup: The screens are then mounted in the automatic printing press. All screens must be positioned precisely so that each color layer of the design prints in registration with the other. Ink is the added to each screen and a squeegee to push the thin ink layer onto the garment.
Printing: Shirt then get put onto the printing pallets under each screen, the press revolves imprinting each color onto the garments.
Curing: To permanently set the ink the printed apparel has to pass through a dryer. This cures the ink ensuring durability and vibrant color lasting.
Finishing: Once all color are printed and cured, the product undergoes final inspection and quality control to ensure the design meets our quality requirements.
Ordering:
When ordering screen printed apparel, there are several important rules or guidelines to keep in mind to ensure a smooth and successful process. Here are some key points to consider:
Minimum Order Quantity:
Size variety: You can mix and match sizes within the total quantity of 12 pieces. For example, you could order 4 small, 4 medium, and 4 large shirts, or any other combination that adds up to 12 pieces.
Design Size: Each design size variation has to meet the 12 piece order minimum. The design size is typically based on the smallest garment size, but keep in mind a 8” front logo on a youth extra small tshirt will look normal but that same design on a adult 2XL shirt will look small.
Design Color: All design colorways must be ordered within the 12 piece minimum For example, if your design has two color variations—say, one with red and black and another with blue and white—you would need to order at least 12 pieces of each colorway to fulfill the minimum order requirement.
Design Placement: Consistency in design placement is crucial. This means that all garments within a specific design variant—whether it’s the left chest, full back, full front, or any other designated area—must have the design placed in the exact same location per 12 piece minimum.
Apparel Blend: It’s essential to note that each fabric blend variation requires specific ink types for printing. Whether it’s cotton, polyester, or blended fabrics, each type needs to meet the minimum order quantity of 12 pieces. This ensures that the right inks are used for each fabric, maintaining quality and consistency in the final printed products.
Artwork Guidelines:
File Formats: Specify preferred file formats for artwork submission, such as Adobe Illustrator (AI), EPS (Encapsulated PostScript), or high-resolution PDFs. These formats are ideal for maintaining vector quality and scalability.
Resolution: Artwork should be created or saved at a minimum of 300 dots per inch (dpi) to ensure high-quality output. Low-resolution images will have to be redrawn into a vector format to maintain a good print quality.
Color Mode: Artwork should be in CMYK color mode for full-color printing or spot color mode (Pantone Matching System, PMS) for precise color matching with specific ink colors.
Vector vs. Raster: We prefer vector graphics for logos, text, and illustrations, as they can be scaled infinitely without loss of quality. Raster images (like photos) should be high resolution and sized correctly for printing.
Fonts: Convert all text to outlines or provide font files to avoid font substitution issues. This ensures that text appears as intended and eliminates the need to have specific fonts installed on our system.
Special Effects: Specify if the design includes special effects like gradients, halftones, or specialty inks (e.g., metallic or glow-in-the-dark). Provide details on how these effects should appear in the final print.
Printing Techniques:
Standard Screen Printing:
Light Garments: We can print up to 8 colors on white or light-colored t-shirts.
Dark Garments: We can print up to 6 colors on dark-colored garments.
This method is suitable for medium to large quantities of apparel.
High Color Count Screen Printing:
For designs requiring more than 8 colors on light garments or more than 6 colors on dark garments, we offer high color count screen printing.
This method allows us to print up to 18 colors, accommodating complex designs with vibrant details.
Ideal for larger quantities or when detailed color representation is essential.
Screen Printed Transfers:
Low Quantity, High Color Designs: For orders under 30 pieces or designs with 4 or more colors (depending on artwork complexity), we offer screen printed transfers.
These transfers are heat applied to garments, ensuring quality and durability similar to direct screen printing.
Suitable for achieving detailed designs on smaller quantities without compromising on color richness or clarity.