What is Screen Printing? Its Functions, and Uses

Many mass printing processes nowadays rely heavily on screen printing. When it became simple to import silk mesh, a crucial element of screen printing, from the East in the 18th century, it initially gained popularity. Because of the simple customization options it provides, screen printing gained popularity in the 19th century and has since spread throughout a variety of sectors, including electronics and retail.

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Although screen printing can be done by hand, particularly for short print runs, it is typically mechanized, utilizing sophisticated inks and materials together with computer technology to produce large quantities of prints. The ability to print on nearly any surface—fabric, paper, glass, wood, card, plastic, or leather—is one of screen printing’s greatest benefits. This article will go over the kinds, applications, and advantages of screen printing.

Screen printing: what is it?

Using a mesh screen, ink, and a squeegee (a rubber blade), screen printing—also referred to as silk screening or silkscreen printing—is the technique of transferring a stenciled image onto a surface. Making a stencil on a mesh screen and then pressing ink to imprint the design on the lower surface is the fundamental step in screen printing. Although metal, wood, and plastic can also be utilized, paper and fabric are the most often used surfaces for screen printing. There are several reasons why this method is so popular, but the most convincing one is the wide variety of colors that may be employed.

How Does It Operate?

The fundamental procedure is always the same whether screen printing is done by hand or with a machine. The printed surface, the generated look, and the type of ink utilized can all vary. The step-by-step screen printing procedure is shown below:

Step 1: Design Development

Design creation is the initial stage in the screen printing process. The chosen design is then printed onto a transparent acetate film, which will be used to make the stencil or screen.

Step 2: Screen Selection and Preparation

The screen and mesh count should be chosen after the design is complete. The total number of fibers in one square inch is known as the mesh count. The design being printed will determine the mesh count you require:

Finer details may be printed with a greater mesh count while maintaining an even ink coating.

Because of their larger apertures, screens with a low mesh count allow ink to pass through.

A coating of light-reactive emulsion is applied to the mesh screen once it has been chosen.

In general, emulsions come in three primary varieties:

Diazo: Less expensive, has a longer exposure time, and isn’t appropriate for intricate prints.

SBQ-based: Ideal for intricate work, it cures very rapidly, requires no mixing, and is costly.

Dual-cure emulsions are a blend of Diazo and SBQ that need mixing, have a shorter total cure time than Diazo, and cost less than SBQ.

Step 3: Making the Emulsion Visible

Under a strong light, the clear acetate film is carefully put on the mesh screen covered with emulsion, causing the emulsion to develop and solidify. It should be mentioned that distinct screens must be utilized for each color when there are several colors used in the design.

Step 4: Making a Stencil

In order to leave a clean impression on the screen, the leftover unhardened emulsion, if any, will be washed away after the screen has been exposed for a certain amount of time. After the screen has dried, the printer will do any necessary touch-ups to ensure the imprint is as similar to the original design as feasible. The stencil is now prepared for usage.

Step 5: Print Preparation

The screen is positioned in the proper location on top of the flattened material on the printing board, ready for printing.

Step 6: Implementing the Design

The printed design will be brought to life in this stage. The printing board is reached by lowering the screen. The top of the screen is inked with the chosen color. The ink will be distributed uniformly along the screen’s length using a squeegee. The design is printed on the object as a result of the ink pressing through the stencil’s exposed sections and transferring onto the underlying silk.

When everything has been printed, the stencil will have fulfilled its function. To repurpose the mesh for making fresh stencils, the emulsion is removed using a specialized washing solution.

Step 7: Finishing and Heat Curing

Finally, a dryer is used to heat-cure the printed product, producing a smooth pattern. This is done in order to prevent the design from fading.

Six Primary Screen Printing Types

Screen printing procedures come in six varieties. Understanding the various categories is crucial since different strategies will yield different outcomes.

1. Color Screen Printing on Spots

Spot color screen printing is the most often used screen printing method. Spot color screen printing prints the stock color of the ink via the mesh stencil. This method creates a bright, solid color patch. When compared to other screen printing techniques, it is far easier to use. For instance, it might be a great choice for printing on t-shirts, jackets, and hoodies.

2. Printing in halftone

Halftone printing prints single colors in gradients. One color of ink is used throughout the process, and when viewed from a distance, this color becomes half-toned, producing a new shade. This method works best for creating the appearance of multi-color printing without really doing it. Additionally, because only one color of ink is required, it is an economical solution.

3. Printing in grayscale

A great way to reproduce full-color photographs as halftones or one-color grayscales is through grayscale printing. If there are more dots in the halftone, the print will appear more detailed. This method is not black and white; rather, it merely extracts the CMY or RGB color scales in various degrees of gray. One of the most economical screen printing methods is grayscale printing, which is frequently used to print black and white patterns on textiles.

4. Printing in Duotone

In order to print the same picture in two colors, duotone printing combines two halftones. First, black ink is used to create a black halftone, and then color ink is used to make a second halftone. The sepia-toned print in photography is comparable to this method. It produces an elegant and creative impression.

5. 4-Color CMYK Printing

It is the most intricate method of screen printing. The four primary colors—cyan, magenta, yellow, and black—are used. The necessary color tones are created by combining these four colors. Although it may be done by hand, for optimal results, it is recommended to perform it mechanically.

6. Printing Simulation Processes

Spot color printing and four-color printing are combined in the simulated printing method. This method is flexible and well-liked by those who want to create lifelike print detail since it works well with both lighter and darker hues.