How to Make a Screen Print

Screen printing (also known as silk screening) is a versatile and popular method for transferring designs onto various materials like fabric, paper, and wood. Below is a comprehensive, step-by-step guide to the traditional screen printing process.

Phase 1: Preparing the Design and Screen

1. Create Your Design:

   • Design your artwork using graphic design software (like Adobe Illustrator or Photoshop).

   • For traditional screen printing, each color in your design requires a separate stencil (and therefore a separate screen). Convert your artwork into solid black and white.

2. Print the Film Positive:

   • Print your black-and-white design onto a transparent acetate sheet using a high-density black ink printer. This creates your "film positive."

3. Coat the Screen:

   • In a darkroom (using safe, low-UV lighting), apply a thin, even layer of liquid photo emulsion onto both sides of your mesh screen using a scoop coater.

4. Dry the Screen:

   • Place the coated screen horizontally in a completely dark, warm room to dry completely. A drying cabinet or a dark closet with a fan works well.

Phase 2: Exposure and Washing

1. Expose the Screen:

   • Place your printed film positive flat against the dried, emulsion-coated screen.

   • Secure it with transparent tape and expose the screen to a strong UV light source for a specific duration (determined by your emulsion type and light intensity). The UV light hardens the exposed emulsion, while the black areas blocked by your design remain soft.

2. Wash Out the Screen:

   • Immediately after exposure, rinse both sides of the screen gently with water using a spray hose.

   • The unexposed emulsion (where your design was) will dissolve and wash away, leaving a clean mesh stencil of your design. Let the screen dry completely.

Phase 3: Setup and Printing

1. Setup the Printing Station:

   • Secure your screen in a printing press or clamp it tightly to a flat table.

   • Place your printing substrate (such as a t-shirt or paper) flat on the printing board underneath the screen. Apply a light spray adhesive to the board to keep the fabric from shifting.

2. Apply Ink:

   • Pour your ink (plastisol or water-based) in a thick line across the top edge of the screen, just above your design. This is called the flood bar area.

3. Pull or Push the Squeegee:

   • Lower the screen so it sits slightly above (or lightly touches) the substrate.

   • Pull a rubber squeegee across the screen at a 45-degree angle with firm, even pressure. This forces the ink through the open mesh areas onto your material.

4. Lift and Inspect:

   • Carefully lift the screen to reveal your printed design.

Phase 4: Curing and Cleanup

1. Cure the Ink:

   • Freshly printed ink must be cured so it becomes permanent and washable.

   • For water-based inks, let them air dry or use a heat press. For plastisol inks, heat them to the manufacturer's recommended temperature (usually around 160°C or 320°F) using a conveyor dryer or heat gun.

2. Clean the Equipment:

   • Immediately clean excess ink off the screen using a screen wash or mild soap and water.

   • If you want to reuse the screen for a new design, apply a emulsion remover to dissolve the hardened stencil, scrub it clean, and rinse thoroughly.