Context
Screen printing (also called silk screening or serigraphy) is a stencil-based printing technique where ink is forced through a tensioned mesh screen onto the substrate using a squeegee. Each color in the design requires a separate screen, with mesh counts typically ranging from 110 (for bold graphics on textiles) to 305 (for fine detail on paper). Plastisol and water-based inks are the two primary ink systems. Plastisol sits on the fabric surface for vibrant opacity, while water-based inks absorb into fibres for a softer hand feel. Screen printing remains the dominant decoration method for apparel runs above 25 units, offering unmatched color vibrancy, Pantone accuracy, and durability at low per-unit costs when amortised across volume.
Process and Applications
Artwork is separated into individual color channels and each color is exposed onto a coated mesh screen using UV light and a film positive or CTS (computer-to-screen) system. Screens are mounted on a manual or automatic press. Rotary automatic presses handle 6-14 color stations and print 400-1,200 garments per hour. Ink is loaded onto each screen, a squeegee pushes it through the open mesh areas onto the garment, and the printed piece moves to a conveyor dryer cured at approximately 160 degrees Celsius to set the ink permanently. Common applications include branded t-shirts, team uniforms, event merchandise, tote bags, posters, and signage. Screen printing also supports speciality effects such as puff ink, metallic and glitter finishes, discharge printing, and high-density raised prints.
Web to Print Context
Screen printing businesses use web to print platforms like InkSoft, Printavo, and DecoNetwork for online storefronts, quote generation, artwork approval workflows, and production management. Customers configure garment style, color, size quantities, and print positions through product builders that calculate pricing based on color count, location count, and order volume. Automated prepress tools separate uploaded artwork into spot color channels and generate screen-ready film positives. Production dashboards track jobs through art approval, screen preparation, printing, curing, and shipping stages, helping shops manage the complex scheduling inherent in multi-screen, multi-location print runs.