How we set up to print your apparel is shown in the illustrations below.
Step 1.
Everything starts with a blank screen. It is made of a fine monofilament mesh. For apparel, we use screens with 110 open holes per square inch.
Step 2.
The screen is coated with photosensitive emulsion. This is done in a darkroom because the coating or emulsion is sensitive to light.
Step 3.
A film positive is created for the design to be printed. The design is sent to a camera shop, and they produce the film positives we need to print your shirts.
Step 4.
The film positive is placed on the coated screen in a darkroom. The black part of the film blocks the screen when it is exposed to light.
Step 5.
After being exposed to light, the film positive is removed and saved for possible reprinting. The screen is prepped for rinsing.
Step 6.
The screen is rinsed with water. The soft emulsion washes out where it was blocked from light. The exposed emulsion hardens in the screen.
Step 7.
The screen is completely dried. The dried emulsion will block the ink. The ink will only go through the opening in the screen - very much like a stencil.
Step 8.
The screen is then set up on the printing press. Pinholes and edges are blocked to make sure no excess ink comes through the screen.
Step 9.
Ink colors are individually mixed for each color used. Solid Coated colors in the Pantone Matching System (PMS) is what we use for our ink color formulas.
Step 10.
Inks are then spread onto a screen. Only one ink color can be used in a screen, so each color in a design requires its own screen and ink color mix.
Step 11.
Ink is pulled across the screen stencil using a squeegee using two strong arms. One color is printed at a time. Inks are cured with heat so they don't wash out.
Step 12.
The shirt is then set with more heat, and the next shirt is loaded onto the press for printing.
