Screen Printing: Durable, vibrant and built to last

Screen printing, also known as silk screening, is a widely used printing technique renowned for its durability and vibrant, opaque colours. The process involves pushing ink through a fine mesh screen onto the garment, creating a design that is not only visually striking but also incredibly resilient. This method is a cornerstone of the custom apparel industry and a service we have perfected since 1984.

The inks used in screen printing are thick and form a distinct layer on top of the fabric. This results in exceptionally bright colours that always stand out, even on dark-coloured garments. After printing, each item is cured at a high temperature, a process which permanently bonds the ink to the fabric, ensuring the design can withstand repeated washing and heavy use without fading or peeling.

When to choose screen printing

Screen printing is the go-to method for projects where longevity and cost-effectiveness at scale are the highest priorities. We recommend this process for:

• Large bulk orders: The screen-printing setup process is more involved than for digital methods, but once complete, it allows for rapid production, making it the most economical choice for quantities of 25 or more.
• Bold, simple designs: It is perfectly suited for logos, text and graphics with a limited number of distinct colours. The results are crisp, clean and impactful.
• Maximum durability: For workwear, team uniforms and promotional items with high usage, screen printing offers a level of durability that is second to none.
• Precise colour matching: We can match specific Pantone colours, ensuring perfect brand consistency across your entire order.

 

Choosing your ink: Water-based vs. plastisol

At John Roberts Associates, we champion sustainable practices and primarily use high-quality, water-based inks. However, we also offer plastisol for specific needs.

• Water-based inks: Our preferred choice. These inks soak into the fabric, creating a softer, more breathable print. They are environmentally friendly and produce a high-quality, non-plastic finish. We use specialised types like Discharge Inks (which remove the garment’s dye to re-colour it, for an ultra-soft feel on dark fabrics) and Opaque Inks for maximum brightness.
• Plastisol inks: A plastic-based ink that sits on top of the fabric, creating a very bright, opaque and durable print. Whilst less environmentally friendly, they are versatile and effective.

 

The screen printing t-shirt process

1. Artwork separation: Your design is separated into its individual colours.
2. Screen creation: A separate mesh screen is created for each colour in your design.
3. Underbasing (for dark garments): To ensure colours appear vibrant on dark fabrics, we first print a white base layer (an underbase).
4. Printing: Each colour is printed one at a time, using a squeegee to push the ink through the corresponding screen.
5. Curing: The garment is passed through a large dryer to cure the ink, resulting in a permanent, durable finish.

 

Limitations and considerations

• Minimum order: Due to the setup involved, screen printing is not cost-effective for very small orders. Our minimum order quantity is 25 items.
• Cost for multiple colours: Each colour in a design requires its own screen, so the cost increases with the number of colours.
• Not ideal for photos: The process is not suited for reproducing photographic images or designs with complex gradients.

 

Have a large project or need durable clothing? Contact our experts to get a quote for our screen printing services or browse our Custom Work T-Shirts & Polos and Personalised & Printed Workwear. We can help with high-quality t-shirt printing.