Screen Printing Process Step by Step

Screen printing is a traditional printing method, also known as the universal printing technique, as it can print on any substrate, supports any color, size, material, and quantity. The ink layer is thick and durable, offering waterproof and UV-resistant properties for 2-5 years. The equipment is simple, the process is straightforward and easy to understand, and it can even be done at home like home screen printing. Next, we will guide you step by step on how to perform screen printing.

File Preparation:

1. Design: Please use Adobe Illustrator, CorelDRAW, or Photoshop to design files in various sizes and colors. This includes spot colors, CMYK gradients, or four-color plus spot colors. For multi-color designs, remember to add overprint settings. Such as : warning labels,car magnets,glow in the dark stickers.
2. Film Output: Use a film printer to output positive film based on the files. Areas with graphics appear black, while areas without graphics remain transparent. Pls check the example as below for American Flag Stickers.

Stenciling Making

1. Screen Frame: Typically aluminum frames are used. Select an aluminum frame of appropriate size based on the artwork dimensions.
2. Screen Mesh: Choose mesh with suitable mesh count according to the artwork and requirements. Higher mesh counts result in denser mesh, producing thinner ink layers and high quality printed image, but also making printing more difficult and prone to ink drying on the screen.
3. Screen Tensioning : Mount the mesh onto a tensioning frame and stretch it at a 45-degree angle. Frame tension should be 15-22 N/cm for sticker , outdoor sticker,car sticker ,window sticker ,reflective stickers printing.
4. Screen Cleaning or Degreasing: Clean and dry newly tensioned or used frames.
5. Emulsion Application: Pour 6-7 layers of emulsion into a squeegee cup. Press the squeegee lip onto the mesh and apply the emulsion from bottom to top. Apply 3-5 coats on each side.
6. Drying: Place the coated frames in a dust-free room for natural drying, or use a hot air gun or drying oven.
7. Exposure: Once the emulsion is dry, immediately expose it. Clean the exposure unit surface, then place the film and screen frame together inside for exposure.
8. Development: After exposure, the non-image areas of the screen harden due to the photoresist’s chemical reaction. The image areas, protected by the positive film, remain soft. Develop these areas using a high-pressure water jet.
9. Touch UP : After development, inspect the screen again to ensure no clogging or dust remains in the image areas and that all non-image areas are completely blocked.

Screen Printing

1. Screen Mounting: Install the prepared screen frame onto the screen printing machine and turn on the printing machine.
2. Blocking Out: Cover non-printing areas with transparent tape to prevent ink from leaking onto the printing table or substrate.
3. Squeegee Selection: Choose a squeegee of appropriate size, angle, and hardness based on the artwork, requirements, and print size. Avoid using squeegees with any nicks, as they severely compromise print quality.
4. Ink Mixing: CMYK inks require no mixing, only adding clear ink or retarder to prevent drying. Spot colors must be mixed to PANTONE specifications. Investing in a high-precision milligram scale significantly improves mixing accuracy.
5. Anti–static Treatment: All substrates must pass through an anti-static device to eliminate static and dust, ensuring print quality. Such as : Static Cling Stickers,holographic stickers,graphic overlays.
6. Drying Rack: Immediately place printed sheets onto drying racks for natural air drying.
7. Ink Reclaiming & Screen Cleaning: At shift end or after printing completion, return excess ink to the ink bucket or container. Clean screens thoroughly with screen cleaning solution.