Screen Printing: A Full Guide To The Process, Key Terms, And More.
The timeless nature of screen printing makes it an incredibly popular technique. The texture, vibrancy, and the way the ink sits perfectly on the substrate make it the ultimate combination of skill and creativity. For decades, this printing technique has been used to bring designs to life, reproduce images, and exercise creativity.
In this article, we cover everything that you need to know about this printing method. From the tools and techniques to the history and modern-day applications, we explore why this method has stood the test of time. At Screen Image, we pride ourselves on being industry leaders, offering reliable and effective printing services for all of your needs.
What is Screen Printing?
It is a printing technique where ink is forced through a mesh screen onto a surface. Certain areas are made impermeable to the ink with a blocking stencil, and the ink that passes through forms the printed image. Screen printing can be performed on materials including PVC Plastic, Chromadek, self-adhesive vinyl, Perspex, corrugated fibreboard, foam board, acrylonitrile butadiene styrene (ABS), Correx, Xanita, Forrex, and floor coverings.
History of Screen Printing
The history goes back over a century. Years of development and innovative refinement have turned a versatile but rare printing method into one of the most popular in commercial use today.
Origins & Adoption in the West
The origins can be traced all the way back to the era of Song Dynasty Art in China, somewhere between 960 – 1279 CE. While the earliest forms of traditional stencilling technique originate from Polynesia, with the cutting of banana leaves and forcing ink through them for the production of a uniquely printed cloth-like product called tapa, the style we know today was first performed by Chinese artists for the production of special masks known as matrixes.
The process was incredibly complicated and required a degree of mastery to perform. The small pieces that create the mask were glued together with human hair, allowing for a perfectly aligned ink passage. The technique was then adapted by Japan, where it was further refined and improved, before making its way to the West.
The printing method was first introduced to Western Europe around the late 18th century, but only achieved large-scale commercial use until 1910, when silk mesh became more available for trade from the East, making it a profitable outlet. In these years, the technique underwent further changes and development as a result of experimenting with photo-reactive chemicals.
Roy Beck, Charles Peter, and Edward Owens researched and experimented with chromic acid salt sensitised emulsions for photo-reactive stencils. As a result, the commercial printing industry was revolutionised with the introduction of photo-imaged stencils, even though it took a few years for this to gain widespread acceptance. Today, this method uses much safer and far less toxic sensitisers.
Key Screen Printing Terms
Ink: Ink is a gel, sol or solution containing at least one colourant, such as dye or pigment, and is used to colour a surface to produce an image, design, or text. The ink is used for drawing or writing with a pen, brush, reed pen, or quill. In letterpress and lithographic printing, thicker inks are used for best results.
Stencil: Stencilling produces an image or pattern on a surface by applying a pigment to a surface through an intermediate object, with carefully placed holes in said intermediate object. The holes allow the ink to reach only some parts of the surface, which creates the design. The stencil functions as both the resulting image/pattern as well as the intermediate object, and the context in which it is used makes it clear which meaning is intended.
Substrate: A substrate refers to the base material onto which images, designs or texts will be printed. The substrate is used in a converting process, such as for printing or coating. The base materials that a substrate refers to may be plastic films, foils, PVC, self-adhesive vinyl, floor coverings, and a range of other options.
Squeegee: A squeegee is a tool with a flat, smooth, rubber blade that is used to remove or control the flow of liquid on a flat surface, often for cleaning and in printing. The squeegee is moved across the stencil to push the ink through and create the design.
What is the Screen Printing Process?
To put it in simple terms, the process is a printing method where ink is pushed through a mesh screen onto a surface, leaving behind a printed image. The stencil blocks the ink from passing through certain areas, which is how the desired design is created. This popular method is especially effective for replicating multiple designs.
Screen Printing Process
The step-by-step process can be summed up as follows:
- Create a Stencil: A stencil is created on a mesh screen, blocking off specified areas that will not be printed. There are various methods in which you can achieve this, such as cutting stencils using paper or using a photo emulsion process.
- Prepare the Screen: The mesh screen is then stretched onto a frame and coated with photosensitive emulsion, which hardens when it is exposed to light and ultimately forms the stencil.
- Apply Ink: Next, the ink is carefully placed on top of the screen.
- Push the Ink Through: A squeegee or blade is then used to push the ink through the open areas of the stencil and directly onto the substrate.
- Repeat for Multiple Colours: Whenever you’re printing multi-colour designs, the process needs to be repeated with different stencils and ink colours.
- Drying and Finishing: Finally, the printed image is left to dry and can be finished further if necessary.
Overall, this technique is an incredibly versatile and effective way to print durable designs onto a variety of different materials, such as PVS plastic, vinyl, floor coverings, fibreboard, and more.
What is Needed for Screen Printing?
For reliable prints, there are a few pieces of specialised equipment that you’ll need. For laying down prints, a full kit is needed for the best results. Without the right equipment, it is difficult to achieve the desired outcomes. Here is a checklist covering all the key pieces of equipment:
Key Screen Printing Equipment
- A printing press: A printing press is one of the most important parts of any print shop. It is a table with clamps to keep the screen in place and maintain precise printing.
- A screen: The screen is a mesh frame that holds the stencil steady and allows the ink to pass through it.
- A squeegee: A squeegee is a rubber blade used to push the ink through the screen and onto the desired surface.
- Ink: Specialised printing ink is needed. You will have to choose between traditional plastisol or water-based and discharge inks, depending on the material and desired outcome.
- A stencil: A stencil is a design created on the screen to determine exactly where the ink is printed.
- Substrates: The substrate is the surface upon which you wish to print, such as paper, plastic, vinyl and other materials suitable for printing.
A flash cure unit: A flash cure unit is a unique piece of printing equipment used to partially cure or flash ink onto a material before the next layer of ink is printed, helping to prevent the ink from blending.
Screen Printing Machine
A machine essentially consists of three main components: the screen, the squeegee and the ink. The machine works by using a mesh tightly stretched and glued onto a frame. A stencil is produced, and ink is pushed through the stencil to print the design.
What Is The Difference Between Screen Printing And Digital Printing?
These two techniques are arguably the two most popular printing methods used in modern day, but there are key differences between the two.
The first difference is found in the colour vibrancy. Digital printing is limited by the CMYK colour gamut, while screen prints use plastisol and water-based inks to achieve vibrant, dynamic colours. With screen prints, it is also much easier to match the exact colour, even more so when using the Pantone Matching System.
While digital prints tend to fade with frequent use and exposure, a high-quality screen print on durable materials can last for several years. Even with regular use under general wear and tear conditions, screen prints can withstand regular usage and exposure without a hint of fading or cracking in the design.
What Type of Paint is Used for Screen Printing?
In general, this method uses water-based or solvent-based inks. They are ready-to-use and come equipped with exceptional colour strength and lightfastness. The thicker ink binds into the material, making it a durable and high-quality print.
Screen Printing Near Me: Why Choose Screen Image?
For the best printing services near you, Screen Image has you covered. Screen Image has a comprehensive range of printing services on offer, including high-quality, reliable screen printing.
As a full-service printing company, we offer creative branding solutions both locally and abroad. At Screen Image, our services are available 24/7, and our output capacity is massive, despite being a relatively small company. We are a client and quality-focused business with years of experience, trained and qualified staff members, and specialised printing equipment.
While we’re screen printing specialists, our other printing services are just as strong. Our digital printing service offers incredibly fast turnaround times, high 1440dpi resolution, and photorealistic images. We cover all digital applications, both indoor and out, including banners, billboards, brand wraps, decals, labels, posters, and much more.
Additionally, we offer label printing services. Our label printing division is well-versed in meeting demanding deadlines, with machines at a potential 9k+ impressions per hour, per machine. And lastly, we are among the major forces in the Spot UV, rub-removable ink and rewettable glue markets.
Final Thoughts: Get High Quality Screen Prints With Screen Image
The versatility, vibrancy and durable nature of screen printing have made it popular through the ages, particularly for producing bold, vibrant designs. From its origins in Asia to the development in Western Europe, this method remains a reliable and effective way of printing.
At Screen Image, we are a full-service printing company committed to providing prints that meet your desired outcomes. Whether you’re mass producing new vinyl prints, adding a unique label to your products, or need imaginative and durable posters printed for promotional purposes, we have the tools, experience and equipment to assist.
Need high-quality prints delivered fast in Cape Town? Get in touch today to receive a free quote or give us a call at +27 21 510 0488 to learn more!