Screen printing is a popular and versatile method for creating custom t-shirts. Despite its widespread use, the process is complex and requires a high level of skill and precision. At Blazon Apparel + Print, we take pride in our expertise in screen printing. In this guide, we’ll dive deep into each step of the screen printing process and explain why it’s not as simple as it sounds.

The Basics of Screen Printing

Screen printing involves creating a stencil (or screen) and applying ink layer by layer. This method is ideal for bold, colorful designs and can produce vibrant, long-lasting prints. Here’s a detailed look at the screen printing process:

1. Creating the Screen

The process begins with creating a screen for each color in the design. At Blazon Apparel + Print, we use advanced CTS (computer-to-screen) machines to create precise and high-quality screens. This technology ensures accuracy and efficiency, reducing the chance of errors.

2. Setting Up the Screen

After the screen is created, it needs to be set up on the printing press. Aligning the screens accurately is crucial, especially for multi-color designs. Even a slight misalignment can lead to poor quality prints.

3. Ink Preparation

Different inks are prepared for each screen. The type of ink used depends on the fabric and the desired finish. At Blazon Apparel + Print, we exclusively use plastisol inks due to their durability, vibrant colors, and versatility.

Why Plastisol Ink?

Plastisol ink is the industry standard for screen printing, known for its many benefits:

• Durability: Plastisol inks are highly durable and can withstand numerous washes without fading or cracking, ensuring your design remains vibrant over time.
• Vibrant Colors: These inks produce bright, opaque colors that stand out on both light and dark fabrics.
• Versatility: Plastisol ink works well on a variety of fabrics, making it a versatile choice for different types of apparel.
• Ease of Use: Plastisol inks are easier to work with and require less precise environmental conditions than other ink types, ensuring consistent quality.

We also offer PMS (Pantone Matching System) color matching, which allows for precise color accuracy to meet specific branding requirements.

4. Printing

At Blazon, we utilize both manual and automatic presses for screen printing. Manual presses are perfect for smaller runs and intricate designs that require more hands-on control. Automatic presses, on the other hand, are ideal for larger orders and ensure consistent quality and efficiency. The t-shirt is placed on the printing press platen, and the screen is lowered onto the fabric. Ink is then pushed through the mesh screen using a squeegee, transferring the design onto the t-shirt. This process is repeated for each color in the design, allowing the ink to dry between applications to prevent smudging.

5. Curing

Once all colors are applied, the t-shirt goes through a curing process. The ink needs to be heated to a specific temperature to set it permanently into the fabric. This ensures the print is durable and can withstand washing without fading or cracking.

The Challenges of Screen Printing

Screen printing is not as simple as it may seem due to several challenges:

Precision and Alignment

Achieving perfect alignment for multi-color designs requires a high level of skill and precision. Misalignment can result in blurry or overlapping colors.

Ink Consistency

Maintaining consistent ink application across multiple prints can be challenging, especially for large orders. Variations in ink thickness can affect the final appearance of the print.

Detail and Intricacy

Fine details can be difficult to reproduce accurately, requiring careful planning and execution. Designs with intricate lines or small text need special attention to ensure clarity.

Material Variations

Different fabrics react differently to inks and curing processes, necessitating adjustments for optimal results.

Why More Colors Cost More

One of the key factors influencing the cost of screen printing is the number of colors in the design. Here’s why:

Additional Screens

For each color in the design, a separate screen needs to be created. This involves additional materials (mesh screens and emulsion) and labor (coating, exposing, and washing out the screens). More colors mean more screens, which increases the setup cost.

Setup Time

Setting up multiple screens on the printing press takes more time and precision to ensure perfect alignment. This setup time is a significant part of the overall production process, and more colors require more setup time.

Printing Complexity

Printing a multi-color design involves multiple passes on the printing press. Each color must be printed separately and allowed to dry between applications. This not only increases the time taken to print each shirt but also requires more attention to detail and quality control.

Ink Costs

Using multiple colors means using more ink. Different colors often require different types of ink or custom-mixed shades, which can be more expensive than standard colors. PMS matching can also add to the cost due to the precision required in mixing custom colors.

Increased Risk of Errors

With more colors, there’s a higher risk of alignment issues, color bleeding, or other printing errors. Ensuring each color layer aligns perfectly requires skill and experience, and any mistakes can result in additional costs for reprints.

The Cost Advantage of Fewer Colors

On the other hand, designs with fewer colors are generally more cost-effective. Here’s why:

Fewer Screens

With fewer colors, fewer screens need to be created, reducing the materials and labor costs associated with screen creation.

Simpler Setup

Setting up a single or two-color design is quicker and easier, reducing the overall setup time and labor costs.

Faster Printing

Printing fewer colors means fewer passes on the printing press, which speeds up the production process and reduces the time taken to complete each order.

Lower Ink Usage

Using fewer colors means less ink is required, reducing the overall ink costs for the project.

Why Fewer T-Shirts Cost More Per Shirt and Larger Orders Cost Less

Another key factor influencing the cost of screen printing is the order quantity. Here’s why smaller orders cost more per shirt and larger orders cost less:

Setup Costs Spread Over More Units

The setup costs for screen printing are relatively fixed, meaning the cost to create screens and set up the press is the same whether you’re printing 10 shirts or 1,000 shirts. For smaller orders, these setup costs are distributed across fewer shirts, making the cost per shirt higher. In larger orders, the setup costs are spread over many more shirts, reducing the cost per shirt.

Economies of Scale

Larger orders benefit from economies of scale. The more t-shirts you print, the lower the marginal cost of each additional shirt. This is because the fixed costs (setup, equipment, and labor) are amortized over a larger number of units, and the variable costs (ink, labor per shirt) decrease with increased production efficiency.

Efficiency in Production

Printing a larger batch of t-shirts allows for a more streamlined and efficient production process. The printing press can run continuously without interruption, reducing the time and labor required per shirt. This efficiency translates into lower costs per unit for larger orders.

Reduced Downtime

With larger orders, there is less downtime between setups and changeovers. This reduces the overall production time and increases the efficiency of the printing process, further lowering the cost per shirt.

The Cost of Skipping on Quality

Choosing a lower-quality screen printing service may save money upfront, but it can lead to various issues that could negatively impact your brand or project:

Poor Print Quality

Low-quality screen printing can result in prints that fade, crack, or peel after just a few washes. This not only looks unprofessional but can also lead to customer dissatisfaction and damage to your brand’s reputation.

Inconsistent Colors

Without the precision of advanced equipment like CTS machines and PMS color matching, you might end up with colors that are inconsistent and do not match your brand guidelines. This can affect the overall appearance and professionalism of your products.

Shorter Lifespan

Inferior inks and improper curing processes can lead to prints that do not last as long. Investing in high-quality screen printing ensures that your custom t-shirts maintain their appearance and durability over time.

Impact on Brand Perception

The quality of your promotional materials reflects on your brand. High-quality screen printed t-shirts can enhance your brand’s image, while poor-quality prints can give the impression of a lack of attention to detail and professionalism.

Technical Aspects of Screen Printing

For those interested in the technical side, here are some additional details:

Mesh Count

The mesh count of a screen determines the level of detail and the thickness of the ink deposit. Higher mesh counts are used for finer details, while lower mesh counts are used for heavier ink deposits.

Emulsion Types

Different emulsions are used depending on the type of ink and the fabric being printed. Diazo, SBQ, and dual-cure emulsions are common types, each with unique properties.

Ink Types

At Blazon Apparel + Print, we exclusively plastisol inks due to their durability, vibrant colors, and versatility. We also offer PMS (Pantone Matching System) color matching for precise color accuracy.

Eco-Friendly Practices

At Blazon Apparel + Print, we are committed to eco-friendly practices. We use water-based inks and sustainable materials whenever possible. Our cleaning and waste disposal processes are designed to minimize environmental impact.

FAQs

What is the minimum order quantity for screen printing?

At Blazon Apparel + Print, our minimum order quantity is 24. This allows us to maintain quality and cost-effectiveness. However, we do offer other printing methods like Direct to Garment (DTG) and Direct to Film (DTF) that provide more flexibility to do smaller runs.

How long does the screen printing process take?

The turnaround time for screen printing varies depending on the order size and complexity. Typically, it takes 2 weeks from the time the design is finalized, though we do offer expedited options that range from a week to as fast as a few days.

Can I use multiple designs in one order?

Yes, you can use multiple designs in one order, but each design will require its own setup and screens, which may affect the overall cost.

Conclusion

Screen printing is a complex and intricate process that requires skill, precision, and attention to detail. The number of colors in your design, the quantity of your order, and the technology used in production significantly impact the cost and quality of your custom t-shirts. At Blazon Apparel + Print, we utilize both manual and automatic presses, as well as advanced CTS machines and PMS color matching, to deliver the highest quality prints efficiently. Understanding the factors that influence the cost can help you make informed decisions about your custom t-shirt projects. Remember, investing in quality screen printing can significantly impact your brand’s perception and the longevity of your custom apparel.

Ready to start your custom t-shirt journey with screen printing? Contact Blazon Apparel + Print today to discuss your design and get a quote!