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Screen Printing

Screen Printing Industry Standards

Apparel screen printing, also known as silk screening, is a popular method for printing designs on clothing and textiles. It involves creating a stencil (or "screen") and using it to apply layers of ink on the fabric. 

Screen printing is known for its durability, vibrant colors, and ability to print on a wide range of materials. It's commonly used for t-shirts, hoodies, and other apparel, as well as posters, bags, and more. The method is cost-effective for larger quantities.

Screen printing is a specialized production process with established industry standards that guide how garments are printed and evaluated for quality. Color appearance may vary depending on garment color, fabric type, ink opacity, and the use of a white underbase on dark garments. Because of this, prints on dark apparel will not appear identical to prints on light apparel, even when the same artwork is used.

Exact color matching requires Pantone (PMS) color specifications provided prior to production. When PMS colors are not supplied, inks are mixed visually based on the provided artwork and standard production practices, and slight color variation is considered normal. Additionally, screen printing does not guarantee exact consistency across different garment colors without approved samples or test prints.

Minor variations in color, texture, and print appearance that fall within these parameters are consistent with screen printing industry standards and are not considered defects.

The Process

  1. Design Creation: The first step is to create the design that will be printed. This design is often created digitally using graphic design software.

  2. Screen Preparation: A screen is made from a fine mesh material stretched over a frame. The design is transferred onto the screen by blocking out areas where ink shouldn't pass through, creating a stencil. This is usually done using a light-sensitive emulsion that hardens when exposed to light.

  3. Ink Application: The screen is placed over the fabric, and ink is poured onto the screen. A squeegee is used to press the ink through the mesh and onto the fabric, only where the stencil allows it to pass.

  4. Curing: After printing, the ink needs to be cured to set it permanently on the fabric. This is typically done using a heat press or a conveyor dryer.

  5. Cleaning: The screen is cleaned and can be reused for the same design or repurposed for a new one by removing the stencil and creating a new one.

Art Work Requirements

When preparing artwork for screen printing, several key requirements and considerations ensure the best possible outcome. Here are the main points to keep in mind:

  1. File Format
    • Vector Graphics: Preferred for screen printing because they can be scaled without loss of quality. Common formats include AI (Adobe Illustrator), EPS (Encapsulated PostScript), and PDF.
    • High-Resolution Raster Images: If vector files aren't available, use high-resolution raster images (at least 300 DPI) to ensure clarity. Common formats include PSD (Photoshop), PNG, and TIFF.
  2. Color Separation
    • Spot Colors: Screen printing typically uses spot colors, where each color in the design requires a separate screen. It's important to separate the artwork into individual colors. This can be done using software like Adobe Illustrator or Photoshop.
    • Pantone Colors: If exact color matching is crucial, specify Pantone colors (PMS). This ensures consistent color reproduction across prints.
  3. Resolution and Size
    • High Resolution: As mentioned, use at least 300 DPI for raster images.
    • Actual Size: Prepare the artwork at the actual size you want it printed, or clearly indicate the desired dimensions.
  4. Line Thickness and Detail
    • Minimum Line Weight: Ensure that lines and details are not too fine. A minimum line weight of 1-2 points (0.25-0.5 mm) is recommended, depending on the screen mesh used.
    • Negative Space: Include sufficient negative space to ensure that fine details don't blend together when printed.
  5. Fonts and Text
    • Convert to Outlines: Convert all text to outlines (vector paths) to avoid font compatibility issues.
    • Legibility: Use fonts that are easy to read and avoid very small text, especially for intricate fonts.
  6. Transparency and Layers
    • Flatten Layers: If using layers in your design software, ensure they are flattened or clearly organized.
    • Avoid Transparency: Transparency effects can cause issues in screen printing and should generally be avoided or converted to solid colors or halftones.
  7. Artwork Approval
    • Proofing: Always get a proof from the printer to approve the colors, size, and placement before starting the full print run.