Screen Printing Process

Last Updates Published: August 15, 2023

Introduction to Screen Printing

A Glimpse into the Past: The History of Screen Printing

Screen printing, also known as silk screening, has its roots in ancient China, where it was used as a method of transferring designs onto fabrics. Over the centuries, this art form travelled across Asia and eventually reached Europe in the late 18th century. Initially, it was a technique reserved for the elite, but with the advent of new materials and technologies, it became more accessible to the masses.

Screen Printing in the Modern Era

Today, screen printing holds a significant place in the world of design and manufacturing. From bespoke T-shirt designs to intricate artworks and even industrial applications, its versatility is evident. One of its standout advantages is the ability to produce multiple copies of the same design efficiently, making it ideal for bulk orders and mass production. In an age dominated by digital technology, the tactile and unique nature of screen printed items offers a refreshing contrast, making it a sought-after printmaking technique for many.

What is Screen Printing?

Screen printing is a method where ink is pushed through a mesh or stencil to print a design onto a substrate. The stencil defines the shape of the design, ensuring that only the desired areas are printed. This process is particularly efficient when replicating a design multiple times, ensuring consistency across all prints.

Commonly Used Materials in Screen Printing

Screen printing isn’t just limited to fabric. The process can be applied to a variety of materials, including but not limited to:

• Fabric: From cotton T-shirts to silk scarves.
• Paper: Used for posters, artwork, and stationery.
• Plastic: For items like promotional materials and decals.
• Glass and Ceramics: For decorative purposes.
• Metal: Often used in industrial applications.

The Science Behind Screen Printing

The Magic of Ink Adhesion

The success of screen printing lies in the way ink adheres to materials. Different inks are formulated to bond with specific substrates. For instance, water-based inks are often used for fabrics, while solvent-based inks might be chosen for plastics or metals. The ink, once applied, needs to be cured, either through air drying or by using heat, ensuring it becomes a permanent part of the substrate.

The Crucial Role of the Mesh

The mesh screen, often made of polyester or silk, is pivotal in the screen printing process. It acts as a barrier, ensuring that ink is only transferred where the stencil permits. The fineness of the mesh can be adjusted depending on the intricacy of the design and the viscosity of the ink. A tighter mesh is used for detailed designs, while a looser mesh might be chosen for bolder prints. The tension of the mesh, it’s cleanliness, and the evenness of ink application all play a role in achieving a flawless print.

This screen printing process guide will walk you through how to silk screen print at home, even if you are a complete beginner.

Sustainable Printmaking Guide

Dive Deeper: Comprehensive Screen Printing Guides

For enthusiasts keen to delve deeper into screen printing nuances, we offer detailed guides for each step of the process. As you navigate our content, keep an eye out for links directing you to these comprehensive resources, ensuring mastery at every stage of your screen printing endeavour. We have also linked these in the boxes below.

The Screen Printing Process Step by Step

Step 1 – Workspace Setup and Equipment Preparation

Crafting Your Screen Printing Sanctuary: Setup and Equipment Preparation

Embarking on the screen printing journey requires not just passion, but also a well-organised workspace and properly prepared equipment. Here’s a guide to setting up your screen printing haven and ensuring your tools are primed and ready.

Setting Up Your Workspace:

1. Location: Choose a well-ventilated area, preferably away from direct sunlight to prevent premature drying of inks.
2. Workspace Layout: Organise your space efficiently. Have a designated area for each step of the process: design creation, screen preparation, printing, and drying.
3. Storage: Invest in shelving or drawers to store screens, inks, and other materials. Keeping items organised will streamline your process.
4. Safety First: Ensure you have a fire extinguisher and first aid kit on hand. Always use gloves and masks when working with chemicals.

Getting Your Equipment Ready:

1. Screen Preparation:
   • Clean your screens thoroughly before each use.
   • Ensure they are free from old ink residues and are tightly stretched.
2. Ink Consistency: Check the consistency of your inks. They shouldn’t be too thick or too runny. Stir them well before use and ensure they’re stored in airtight containers to prevent drying out.
3. Test Your Squeegees: Ensure the rubber edge of your squeegee is smooth and free from nicks or cuts, which can affect the quality of your print.
4. Press Maintenance: If you’re using a printing press, ensure it’s clean and well-maintained. Regularly check for any loose parts and ensure it’s calibrated for accurate printing.
5. Trial Run: Before diving into your main project, always do a test print. This helps you adjust the pressure, ink consistency, and screen alignment as needed.

Remember, a well-set workspace and meticulously prepared equipment are the foundations of a successful screen printing project. Taking the time to get these right will ensure smoother operations and higher-quality prints.

What Tools, Equipment & Materials Do You Need for Screen Printing?

Step 2 – Decide What to Print On

Equipment Needed

Choosing the Right Screen: Paper vs. Textiles

Before diving into screen printing, it’s essential to determine your preferred medium: paper or textiles. This choice will influence the type of screen you’ll need.

Tips for Making the Right Choice:

1. Textile Printing:
   • If you’re keen on textile printing (like DIY T-shirt printing at home), opt for a screen with a lower mesh count, around 43T. This allows a generous amount of ink to penetrate the fabric.
   • The rationale? Fabrics require more ink to ensure durability, especially after multiple washes.
2. Paper Printing:
   • For paper projects, a screen with a mesh count of at least 90T is recommended. Personally, I gravitate towards 120T for my endeavours.
3. Understanding Mesh Count:
   • The mesh size reflects the number of mesh threads per square inch. A higher mesh count translates to a finer mesh, while a lower count indicates a coarser mesh.

By understanding the nuances of mesh counts and aligning them with your printing medium, you’ll set the stage for optimal screen printing results.

Paper VS Textile Screen Printing

There are pros and cons for printing on paper and textiles, each of them have their own uses which are case dependent on what you want to create/produce. For the purpose of this guide, we will be covering textile printing on t-shirts, however, this process can also easily be used for paper printing. Throughout the screen printing guide I’ll recommend alternative materials where there are any changes in the technique for paper/textiles.

It enables you to produce multiple copies of the same artwork, with the potential to make each with their own character so no print is the same! This can be achieved by trying different coloured inks or papers. You’ll be surprised to know that a lot of products and things around you are in fact screen printed!

Types Of Mesh For Screen Printing

Screen printing, a versatile method of imprinting designs onto various substrates, relies heavily on the type of mesh used. The choice of mesh, traditionally made from silk but now predominantly crafted from synthetic polyester materials, determines the clarity, detail, and ink saturation of the print. Whether printing on textiles, which require a more porous mesh to ensure vibrant ink absorption, or on paper, which demands a tighter mesh for sharp details, the mesh count plays a pivotal role. As the intricacies of selecting the right mesh can be nuanced, we’ve compiled a comprehensive guide on the subject. Dive into our detailed guide for an in-depth exploration and to make informed decisions for your screen printing projects.

Step 3 – Preparing Your Screen Mesh For Printing

Equipment Needed

Pristine Printing: The Art of De-Greasing Your Screen

For optimal screen printing results, it’s essential to start with a clean slate. De-greasing your screen ensures that the emulsion adheres properly to the mesh, and even if you’re not using emulsion, a clean screen is crucial to prevent ink contamination.

Steps and Tips for Effective De-Greasing:

1. Choose the Right Agent: Opt for a high-quality degreasing agent like Pregan NT9 to ensure thorough cleaning.
2. Sponge Cleaning: Wear gloves and use a sponge to scrub the screen gently, ensuring all areas are covered.
3. Safety First: Always wear goggles to protect your eyes from any potential chemical splashes.
4. Rinse Thoroughly: Post-cleaning, rinse the screen with water to ensure no degreasing agent residue remains.
5. Drying: Pat the screen dry with clean towels or rags. For best results, leave it in a dust-free area to air dry completely.

By following these steps, you’ll set the foundation for a flawless screen printing experience, ensuring clarity in designs and longevity in prints.

Equipment Needed To Coat Screen Mesh With Emulsion

YOU CAN SKIP THIS STEP IF YOU WANT TO USE A HAND CUT STENCIL, CHECK THIS GUIDE.

Perfecting the Emulsion Process: Coating Your Screen in Dim Light

When embarking on the silk screen printing journey at home, the emulsion process is a pivotal step. Given that emulsion is UV-sensitive, it’s crucial to work in a dimly lit environment, ideally during the evening, to prevent premature exposure.

Guidelines and Tips for a Flawless Emulsion Coating:

1. Prepare Your Workspace: Ensure you’re in a dark or dimly lit room. This not only protects the emulsion but also ensures clarity in your final design.
2. Application Technique:
   • Pour the emulsion into a trough or scoop.
   • Holding the scoop at a 45-degree angle, start applying the emulsion from the bottom of the screen, working your way upwards. Aim for a consistent, even coating.
3. Manage Excess Emulsion: Once coated, tilt your screen upright and use the scoop to capture and remove any excess emulsion.
4. Drying: Position the screen horizontally on a flat surface within the dim room to dry.
5. Maintain a Clean Environment: It’s essential to keep the drying area as dust-free as possible. Dust particles can contaminate the drying emulsion, potentially compromising the clarity of your design during exposure.
6. Learn from the Experts: For a visual guide, consider watching tutorials. For instance, “How to Coat a Screen with Photo Emulsion” by Hand Printed offers valuable insights.

By meticulously following these steps and tips, you’ll lay the groundwork for a successful screen printing project, ensuring crisp designs and lasting impressions.

Step 4 – Design & Planning For Screen Printing

Equipment Needed

Crafting the Perfect Stencil: A Comprehensive Guide to Screen Printing Preparation

Screen printing is as much about the art as it is about the technique. A crucial part of this technique is creating the perfect stencil. Here’s a deep dive into the methods and best practices for stencil creation and design planning.

Methods for Creating Stencils:

1. Light-Sensitive Emulsion:
   • This is the most favoured method, allowing printers to reproduce hundreds of copies of their design.
   • It’s ideal for intricate designs and hand-drawn illustrations.
   • The challenge lies in the requirement for dedicated space and specific equipment to expose the screens.
2. Paper Mask:
   • A simpler method, especially for beginners or those looking for a quick print.
   • It’s limited by its durability, especially with designs that require multiple prints.
   • The advantage is the minimal equipment and chemicals needed for cleanup.

Design Creation and Preparation:

While hand-drawn designs have their charm, using software like Photoshop can simplify the editing and layering process. If you’re looking to transform a drawing into a print-ready design, vector conversion is your best bet.

• Resources:
  • Dive into our guide on preparing artwork for screen printing.
  • Learn how to convert a drawing into a vector with our dedicated guide.
  • For Adobe Illustrator enthusiasts, here’s a guide on preparing artwork for screen printing.
  • For a visual guide, watch this video on printing screen print transparencies by NateScreenPrints.

All designs should ideally be printed onto transparency paper or acetate. If you’re environmentally conscious, tracing paper is a viable alternative. Ensure the design is opaque. For best results, use a toner printer or consult a professional printing service.

Design Planning Tips:

• Size Matters: Ensure your design is slightly smaller than your screen.
• Colour Limit: Stick to a maximum of three colours (just for this guide), as each colour requires a separate layer.
• Layering Logic: Overlap lighter colours with darker layers for better visibility.
• Alignment: Incorporate registration marks in your design to align layers during printing. For a visual guide, refer to this YouTube video on screen registration.
• Printing: Once satisfied with your design, print it on the rough side of your chosen transparent medium (depends on printer type) using high-quality settings. Ensure the design is opaque to block light from reaching the emulsion, and always allow it to dry thoroughly.

With these guidelines in hand, you’re well-equipped to embark on your screen printing adventure, ensuring designs that are both beautiful and technically sound.

Films, Positives & Stencils For Screen Printing Exposure

Mastering the art of screen printing begins with understanding the intricacies of films, positives, and stencils. These foundational elements play a pivotal role in determining the clarity, precision, and vibrancy of your final prints. Whether you’re navigating the nuances of high-contrast film positives or exploring the best materials for durable stencils, our comprehensive guide provides in-depth insights and expert tips to elevate your screen printing game. Dive into the world of screen printing exposure with our detailed guide and ensure every print stands out with impeccable quality.

Aligning Perfection: Setting Up Screen Printing Stencils for Multi-layered Designs

Once you have your design ready on vellum or acetate, the next crucial step is ensuring each layer aligns perfectly on the screen. Proper alignment is the key to crisp, multi-layered prints that look professional and seamless.

Steps and Tips for Stencil Alignment:

1. Preparation:
   • Ensure your screen is clean and free from any previous ink or emulsion residues.
   • Position your screen on a flat, stable surface with good lighting.
   • Work in low light conditions to prevent premature exposure of the screen.
2. Placement of the First Layer:
   • Begin by placing the first layer of your design on the screen. Ensure it’s centred and aligned to your desired position.
   • Use low-tack tape or registration tabs to temporarily hold the design in place.
3. Registration Marks:
   • Incorporate registration marks on your design. These are small marks outside the main design area that help in aligning subsequent layers.
   • Ensure these marks are visible on every layer of your design.
4. Layering:
   • Once the first layer is set, carefully position the next layer using the registration marks as a guide. This ensures each layer is perfectly aligned with the previous one.
   • Repeat this process for each layer, always cross-referencing with the registration marks.
5. Securing the Design:
   • Once all layers are aligned, secure the design onto the screen using tape around the edges. This prevents any movement during the printing process.
6. Test Print:
   • After exposing screens in the next step, before diving into the final print, always do a test print on scrap material. This helps identify any misalignments or issues that might need correction.

Additional Tips for Precision:

• Square Alignment: Keeping the vellum or acetate square with the screen can significantly aid in maintaining consistent alignment across all layers.
• Registration Mark Taping: While registration marks are essential for alignment during test prints, they can be taped over during the final print to ensure they don’t appear on the final product.

By meticulously following these steps and ensuring each layer aligns perfectly, you’ll achieve multi-layered screen prints that are sharp, vibrant, and professional.

Step 5 – Exposing Your Screens

Equipment Needed

Illuminating Your Design: The Art of Screen Exposure

Once your design is prepped, the next pivotal step in the screen printing process is exposure. This involves transferring your design onto the screen coated with dried emulsion, all within the confines of a dimly-lit room. The magic happens when light interacts with the emulsion, setting the stage for your final print.

Guidelines and Tips for Effective Screen Exposure:

1. Setting the Stage:
   • Return to your dimly-lit room with the screen coated in dried emulsion.
   • Lay your design, printed on film or transparency paper, atop the screen, readying it for light exposure.
   • Lay a sheet of glass, ideally strengthen glass on top to help keep your design flat. The heat may warp the acetate, when using UV lights this is less likely to happen.
2. Exposure Technique:
   • For a setup with a 1000w light, approximately 4 minutes of exposure is ideal at 15 inches away from the the screen. However, this can vary based on the distance and wattage of your light source or if using UV lights.
   • Post-exposure, use a jet wash to rinse off the unexposed emulsion.
3. Tips for Optimal Exposure:
   • Place a block of blackout material beneath the mesh area of your screen. Position your design snugly on the mesh side. To ensure a flat, gap-free surface, lay a sheet of glass on top.
   • Exposure time can differ based on the distance between your screen and the light, as well as the light’s power. Use provided charts or the subsequent tip as a guide.
   • To fine-tune using my 1000w light, positioned about 15 inches from the screen, I exposed it for roughly a minute. After switching off the light, I shifted a piece of paper along and exposed for another minute. I repeated this process over different sections of the screen for about 5 minutes to determine the best exposure times for my setup.
   • The light causes the emulsion to harden and adhere to the screen mesh. Where your black image is, the light is obstructed, keeping the emulsion water-soluble.
   • For a deeper dive into timing adjustments, refer to resources like “Hunt The Moon Exposure Times“.
   • Steer clear of direct sunlight during this phase, as it can inadvertently expose and ruin the design you’ve just transferred onto the screen.
   • Finally, rinse the screen with water (a pressure washer is particularly effective here), washing away the non-adherent emulsion where your image was. This clear patch is where the ink will pass through during printing.

By meticulously following these steps, you’ll ensure a crisp, clear design transfer, setting the foundation for a successful screen printing project.

Information for the 2 charts taken from:Wikibooks Screen Printing

Lights For Screen Printing Exposure

The art of screen printing relies heavily on the precision of exposure, and the right lighting is paramount to achieving impeccable results. Whether you’re using UV lamps, halogen floodlights, or even the natural rays of the sun, the choice of light source can significantly impact the clarity and detail of your prints. For those keen on delving deeper into the intricacies of screen printing exposure and understanding the nuances of various light sources, our detailed guide offers comprehensive insights.