The Screen Printing Process: A Comprehensive Overview

1. Design Creation

The journey begins with the design and there are thousands of talented artists all over the world that can help you adapt any idea or artwork into something that can be imprinted with the screen printing process. Even now, many companies, including us at Cut Form LLC and ArgoTex, are using AI to help our idea generating process in conceptualizing something that will be produced for the screen.

2. Screen Preparation

Next, we move to the heart of screen printing: the mesh screen. Here’s how it’s done:

• Emulsion Application: A light-reacting product called emulsion is applied to the mesh screen. The emulsion-covered screen is then dried.
• Artwork Placement: A clear film with the dark art (the design) is placed on the screen.
• Exposure: A light is cast onto the screen. The areas under the dark art remain soft, while the other areas harden. In effect, a "stencil" is created. Depending on how many color layers there are, new screens will be produced.

3. Prepare for Print

Once the design and screen are ready, the screen is carefully positioned onto the printing press. The fabric or material to be printed is also prepared. This step involves:

• Choosing the Right Mesh Screen: The printer selects a mesh screen based on the complexity of the design and the texture of the fabric.
• Ink Selection: The ink type (plastisol, water-based, or specialty inks) is chosen based on the desired outcome.
• Registration: Ensuring precise alignment of the screen with the substrate.

4. Pressing

The actual printing process takes place on the press. Here’s how it works:

• Ink Application: Ink is placed on the screen.
• Squeegee Action: A squeegee is used to push the ink through the open areas of the stencil (the design) onto the fabric.
• Repeat: The process is repeated for each color in the design. Multiple screens may be used for multicolor prints.

5. Curing

After printing, the ink needs to cure or set. This is typically done using a conveyor dryer. The heat cures the ink, making it permanent and wash-resistant.

6. Quality Control

Quality control is crucial. Inspecting each printed item ensures that the design is sharp, colors are accurate, and there are no defects.

7. Cleaning and Reclamation

The screens used for printing need to be cleaned and reclaimed. This involves removing the ink, reclaiming the emulsion, and preparing the screen for the next job.

8. Packaging and Distribution

Once the prints are dry and quality-checked, they are ready for packaging. Commercial screen printing businesses package the finished products and distribute them to clients or retailers.