Top 8 Types of Screen Printing Process In 2023

The process of screen printing involves several steps to create a print using a mesh screen, ink, and a squeegee. Here is a detailed explanation of the screen printing process:

Design preparation:

The first step in screen printing process is to prepare the design or image that will be printed. This can be done digitally using graphic design software or by creating a hand-drawn design. The design is typically created in layers, with each layer representing a different color or element of the final print.

Screen preparation:

A mesh screen is selected and prepared for the printing process. The screen is usually made of polyester or nylon and is tightly stretched over a frame.

The screen is coated with a layer of photosensitive emulsion or a stencil film, depending on the chosen screen printing method.

Stencil creation:

In the photosensitive emulsion method, a positive image of the design is printed onto a transparent film or a specialized emulsion-coated film.

The film is placed on top of the prepared screen and exposed to ultraviolet (UV) light, which hardens the emulsion in the exposed areas.

The unexposed areas of the emulsion remain soft and can be washed away using water, leaving behind the stencil on the screen. In the direct stencil method, a stencil film or paper with the design cut out is adhered to the prepared screen using a stencil adhesive. The exposed areas of the design are cut or peeled away, leaving the desired stencil on the screen.

Set-up and registration:

The screen is mounted onto a screen printing press, which holds it securely in place during the printing process. Registration marks are placed on the substrate and the screen to ensure accurate alignment of the design during each print.

Ink preparation:

The desired ink colors for the design are selected and prepared. Screen printing inks can be water-based, plastisol, or specialty inks such as metallic or fluorescent inks. The inks are mixed and adjusted to achieve the desired colors and consistency for printing.

Printing:

The substrate to be printed, such as fabric, paper, or plastic, is placed on the printing press. The screen with the prepared stencil is positioned over the substrate, aligning it with the registration marks. A specific amount of ink is poured onto the screen, near one end of the design. A squeegee, typically made of rubber or other flexible material, is used to pull or push the ink across the screen, exerting pressure to force the ink through the open areas of the stencil and onto the substrate.

The squeegee is moved in a smooth and consistent motion to ensure even distribution of the ink. This process is repeated for each color or layer of the design, with the screens and inks being changed accordingly.

Curing and drying:

Once the printing is complete, the printed substrate is moved to a drying or curing station. The curing process varies depending on the type of ink used. Water-based inks may be air-dried or heat-set, while plastisol inks require heat curing to bond with the substrate permanently. Heat curing is typically done using a conveyor dryer or heat press, where the printed substrate is exposed to the required temperature for a specific duration.

Finishing:

After the ink is cured and dried, the printed substrate may undergo additional finishing processes, such as washing or ironing for textiles, trimming excess material, or any other post-printing treatments as needed.

By following these steps, the screen printing process allows for the creation of high-quality, durable prints with vibrant colors and intricate details.