screenprinting 101

The image you see above simulates how we go about screenprinting a multiple colored job. A separate screen needs to be burned for each color of ink that will be printed on the shirt.


Step 1-Artwork Stage
During this stage of the screenprinting process, our artists go to work creating innovative custom designs to fit each client's needs. They size the artwork to fit each position on the shirt, and then the client is contacted to finalize the design size, colors, and overall appearance. Once finalized, the design is broken into separate colors and printed on transparencies or plates. These transparencies are then passed on to the screen room for the burning process.

Photo 1-Our artist goes to work on the computer. Photo 2-Approved design is separated and printed on special paper.


Step 2-Burning to Screens
Transparencies from the artwork stage are taped to tightly meshed screens. These screens have already been coated and dried with a special light sensitive photo polymer screen emulsion. This emulsion turns very hard when exposed to light. The transparencies prevent light from hardening the polymer on designated parts of the screen when it is exposed on the burn table. The emulsion hardens in an exposure time of approximately 3-5 minutes. From here, the screen is taken to a high pressure wash tub where the unhardened portions of the polymer are blown out. This leaves a template screen that can be used to print shirts.


Photo 1- The separation is attached to a screen which is coated with a photo sensitive material. Photo 2-The screens are placed in the exposure unit. Photo 3-The screen is placed in the wash tub to soak. Photo 4-The screen is being washed out.


Step 3-The Printing Process
The printing process is done on print presses depending on the quantity of the order. The burned screens are attached to the top of each station, and they are set to move up and down. The shirt is placed by hand onto a palette which rotates to each station. Once at a station, the screen moves down and a squeegee is drawn across the screen pushing ink through the open mesh onto the shirt. At each station the shirt picks up another color until it has revolved around through the print cycle. Once the design is finished being printed it must be dried.


Photo 1- The screen is attached to the press. Photo 2-The art is being printed manually onto a shirt.


Step 4-Drying & Completion
At this stage, the shirt is placed on a conveyor belt to run through a 350° dryer so the ink will cure. This prevents the ink from fading or washing out in the laundry. The shirts are then "caught" at the end of the dryer. From here, they are counted, inspected and then boxed. These boxes are then labeled to await pick-up by the client.


Photo 1-The shirt is being run through the dryer. Photo 2-The shirts are stickered and placed in a box.

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