What is Screen Printing: Your All-in-One Roadmap

Still looking for a printing method that’ll produce vibrant and durable results while maintaining versatility and cost-efficiency?

Screen printing might just be it.

In this guide, we’ll break down the screen printing process, explore how it works, and dive into its pros and cons. By the end, you’ll understand what screen printing is and whether it’s the right choice for your print-on-demand needs. 

Whether you’re a business owner, artist, or hobbyist, you’ll gain the insights you need to make an informed decision. Let’s dive in!

What is screen printing?

Screen printing—also known as silkscreen printing—is a method where ink is applied to a surface through a mesh screen that holds a stencil. The stencil allows for the precise placement of ink in specific areas, creating a printed image. 

How does screen printing work?

First, the design is separated into different layers based on the unique colors of the imagery. Each layer is then printed on independent  transparent films, which are used to create the stencils on  mesh screens (one screen per film) which are coated with a light-sensitive emulsion. The emulsion hardens when exposed to light, and the areas of the design are washed out, leaving a clear stencil.

Next, the material is placed onto a printing platten directly under the screen, and ink is spread over the stencil with a squeegee. The ink passes through the open areas of the stencil, transferring your design onto the material. This is repeated until each layer is applied to the material to create your final printed image!

After the design has been transferred, the final important step is curing the ink. This is typically done with heat to ensure the ink adheres to the material properly. Heat curing makes the design long-lasting and able to withstand repeated washing.

Screen printing pros

One of the standout advantages of screen printing is its durability. Because the ink used in this process is much thicker than that used in digital printing techniques like DTG, the result is a more durable design. Even with the thinner, water-based inks that are becoming more and more common in the screen printing industry, durability is still generally considered very strong for apparel printing. 

Screen printing also excels at producing vibrant, bold colors (even on darker fabrics), which helps designs stand out. It’s a popular choice for printing bold designs, like logos, text, or monochromatic images, where only a few colors are needed. This makes it ideal for t-shirt printing and other apparel. 

It’s also highly cost-effective for bulk orders—once the screen is prepared, the printing process is extremely efficient and becomes cheaper. Screen printing is often the preferred choice for businesses and print shops that need to produce large quantities of printed garments with the same design. However, for small orders or intricate designs, you might want to explore alternatives like direct-to-garment (DTG) or direct-to-film (DTF), which we’ll cover later.

Another core benefit of screen printing is the capability to color match quite precisely which is often a must for clients working with trademarked logos and designs. As ink is generally hand mixed in screen printing to create the needed colors, color code standards such as Pantones can be matched exactly.

Additionally, special effects can be applied with screen printing such as glitters or foils, providing unique options of expression not present with digital printing.

Finally, screen printing is used on a variety of materials, not just fabric. It can be applied to glass, wood, and even metal.

Valuable read: What’s the Best Method for Printing T-Shirts

Screen printing cons

While screen printing has its advantages, it comes with some limitations for those looking to offer a wide range of designs. 

One of the biggest drawbacks of screen printing is the time and cost involved in setting up the screens. For each color in a design, a separate screen must be created, which makes this process less efficient and costly for small orders. Due to this, screen vendors almost always have minimum order quantity requirements with costs reducing as increased.

Additionally, traditional plastisol inks used in commercial screen printing can be harmful to the environment if not disposed of properly. While there are eco-friendly ink alternatives, they may not always match the vibrancy of standard inks.

While screen printing excels in producing simple, bold designs, it’s not the best option for highly intricate, multi-colored artwork or one-off orders. Other printing methods, like DTG and DTF printing, are more flexible and better suited for customization. For anyone exploring how to start a clothing brand, offering custom design additions can be crucial for standing out in a competitive market.

What equipment will you need?

To start screen printing, you’ll first need to invest in equipment, like mesh screens and the required development and reclaim devices for them, racks for printing and drying, and special fabric inks. Below, we’ve gathered a list of key tools you’d need to get up and running.

Screen frames

Screen frames serve as the structural foundation for the screen printing process. Typically made of metal or wood, these frames are meticulously stretched with fine mesh fabric, in most cases polyester, which acts as the stencil carrier. The mesh thickness and thread count can be adjusted to suit the texture of the surface or fabric.

Mesh screens

The heart of screen printing lies in the mesh screens. Traditionally crafted from silk thread (hence the name “silk screen printing”), modern screens now predominantly use polyester fabrics, offering similar performance at a more affordable price.

After being coated in emulsion and exposed to light, the mesh screen serves as the stencil for the printing process and can be reused after cleaning.

Squeegee

The squeegee, equipped with a rubber blade and a handle, plays a pivotal role in the screen printing process. Its function is to evenly push the ink through the mesh screen onto the material being printed.

The squeegee firmness depends on the design’s complexity. For example, firmer rubber blades excel at intricate designs with fine details, while softer, more yielding rubber squeegees are used for less detailed prints or fabric applications.

Inks

Inks are the creative soul of screen printing. These specialized inks come in various forms, each designed to achieve distinct effects on the final product. You can choose from a range of inks, including glittery, texturized, or even puff inks, which expand to create raised surfaces, allowing for unique visual and tactile elements.

Selecting the right ink type is also influenced by the material being printed on, with specific inks designed for machine washability, ensuring the longevity of printed apparel.

Screen printing press

While screen printing can be done manually with a mesh screen and a squeegee, many will opt for a screen printing press to make the process efficient. Screen printing presses help make the process efficient by securing the screen and allowing for swift material changes.

In general, there are three main types of presses: manual, semi-automatic, and automatic. The choice of press often depends on the volume of printing required, with larger-scale operations favoring semi-automatic or automatic options.

Washing station

After the screen printing process is complete, the screens must be thoroughly cleaned to remove all emulsion traces. Proper cleaning ensures that screens remain in excellent condition for future print runs.

How does screen printing compare to other methods?

As digital printing technologies continue to evolve, it's important to understand how screen printing stacks up against other popular printing methods. In this section, we'll compare screen printing with DTG (direct-to-garment), DTF (direct-to-film), and sublimation printing, highlighting the strengths and best-use cases for each method.

DTG vs. screen printing

DTG is a digital printing method that uses specialized inkjet technology to produce high-resolution, full-color prints. The digital nature of DTG makes it ideal for complex artwork with multiple colors, gradients, or fine details that would be difficult and time-consuming to achieve with traditional screen printing.

One of the key differences between DTG printing and screen printing is how they handle color. Screen printing requires a separate screen for each color, which increases both the time and cost of production. In contrast, DTG can print hundreds of colors at once without the need for multiple screens, making it perfect for multi-color artwork or designs with fine details.

DTG works best on light, natural fabrics like cotton, bamboo, and linen, as the ink bonds well with natural fibers. For synthetic fabrics, however, screen printing is the more reliable option, as it performs better on materials like polyester however special treatments or inks may still be necessary.

A key advantage of DTG printing is its ability to work with digital files. Since the process is entirely digital, designs can be easily adjusted, resized, or customized on the fly. This flexibility means that businesses can print one-off designs or small custom orders without any additional setup costs. 

For example, a customer could request a t-shirt with a photo or custom text, and the DTG printer would handle it with no need for special preparation. In contrast, screen printing requires a new screen to be created for each design change, so screen printing is more time-consuming and costly when design variations are needed.

You can find out more about DTG printing in our complete guide: DTG vs. screen printing.

DTF vs. screen printing

DTF printing uses a digital process to transfer designs onto film, which is then heat-pressed onto fabric. This allows for highly detailed designs with sharp, smooth finishes.

DTF printing works well on synthetic fabrics like polyester, fleece, and nylon, making it an excellent option for sportswear, outdoor gear, and activewear. These materials are commonly used for high-performance clothing, where flexibility and durability are key. 

Screen printed designs look great on natural fabrics like cotton, but for synthetic blends, DTF offers better adhesion and longevity. While screen printing can also be used on synthetic fabrics, it may not hold up as well as DTF over time, especially when undergoing frequent washing or intense physical activity. 

Another advantage of DTF is its versatility in color options. DTF prints can have virtually unlimited colors and gradients without the need for additional screens or steps. Screen printing, by contrast, is more suited to simple, bold designs where fewer colors are required, as each additional color necessitates a new screen, increasing production time and cost. This makes DTF printing a great option for those who want to produce detailed designs in small quantities or need the flexibility to handle multiple design and size variations without significant setup costs.

However, screen printing still has advantages when it comes to bulk orders and designs that need to last over time. While DTF offers superior color detail, the inks used in screen printing are typically thicker and more durable, making them resistant to wear, fading, and cracking. Additionally, screen printing offers a textured, tactile quality that DTF can’t replicate, making it a favorite for certain applications where the feel of the ink is part of the design’s appeal.

In terms of cost-effectiveness, DTF is more practical for short runs or one-off designs. Screen printing, on the other hand, becomes significantly more economical for large-scale orders.

Sublimation vs. screen printing

Sublimation printing is known for its ability to create all-over designs that cover the entire surface of a garment or product. 

The sublimation process works by turning ink into gas without passing through a liquid state, which allows it to bond with synthetic fibers like polyester. The heat causes the ink to permeate the fabric, essentially becoming part of the material itself. The result is a vibrant, long-lasting print that won’t crack, fade, or peel over time. 

Sublimation printing works best on fabrics with a high polyester content, ideally 100% polyester or a polyester blend. Fabrics like nylon, spandex, neoprene, and lycra are not ideal for sublimation because they lack the necessary polymer structure to bond with sublimation dyes as effectively as polyester.

These materials can melt or become damaged when exposed to the high temperatures required for sublimation, typically ranging from 180°C to 200°C (356°F to 392°F). Nylon and spandex, for example, can warp or melt, while neoprene can lose its shape at such high temperatures.

One of the major advantages of sublimation printing is its ability to produce vivid, full-color designs with an impressive level of detail. Since the ink becomes part of the fabric itself, the result is a smooth, natural finish that doesn’t add any weight or texture to the fabric.

In addition to fabric printing, sublimation is also popular for products like mugs, mouse pads, and phone cases, making it a versatile option for those interested in dropshipping.

However, sublimation does come with some limitations. The process relies on a four-color (CMYK) printing model, which means it can’t replicate specialty inks like metallic, glitter, or textured finishes. If your design requires unique visual effects like raised inks, glow-in-the-dark elements, or glitter accents, screen printing is the better option. 

It’s also important to note that sublimation works best on light-colored fabrics. The sublimation process doesn’t include a white ink layer, meaning the ink will blend with the underlying color of the fabric. For this reason, screen printing is a better choice when printing on dark or black fabrics. Plus, the screen print method works on a wider range of materials, including both synthetic and natural fibers like cotton.

You can find out more about sublimation printing in our complete guide: sublimation vs. screen printing.

Why screen printing remains a top choice

The screen printing industry has a long history of providing durable printing solutions. Whether you’re creating custom t-shirts, promotional materials, or fine art prints, screen printing technology provides unmatched color quality, which makes it a popular choice for large-scale projects.

While newer printing techniques like DTG and DTF have greater flexibility, particularly for small runs and intricate designs, screen printing continues to be favored for printing text and bold, vibrant designs.

Now that you’ve learned the ins and outs of this printing technique, it’s time to dive in and start creating your next project with confidence. Happy printing!

Read next: Embroidery vs Screen Printing: Which Should You Go With?