What is screen printing?
Screen printing is a printing method where you use a mesh screen, ink, and a squeegee to manually transfer a design onto a flat surface. The person creates a stencil on the screen, then pushes ink through it to imprint the design onto materials like fabric, paper, or plastic.
Screen printing – also called silk screening or silk-screen printing – uses surface-specific inks, such as solvent-based, plastisol, or UV-curable inks designed for non-porous materials.
To create a stencil, printers may:
- Block parts of the screen with tape or glue.
- Paint directly onto the mesh using screen blockers.
- Use a light-sensitive emulsion and expose it to light, similar to developing a photo.
Designs can use a single color or multiple layers of ink. For multicolor prints, you must use a separate screen and stencil for each color layer.
How does screen printing work?
The most common method of screen printing uses a light-sensitive emulsion to create detailed stencils. This process creates clean, multi-color designs on various surfaces.
- Design Prep: The artwork is printed on transparent film to block light during exposure.
- Coating: A mesh screen is coated with light-sensitive emulsion.
- Exposure: The film is placed on the screen and exposed to UV light; the emulsion hardens except where blocked by the design.
- Washout: Unhardened emulsion is rinsed away to create the stencil; the screen is dried and touched up.
- Setup: The screen is mounted on a press, and the item is positioned.
- Printing: Ink is pushed through the stencil with a squeegee, transferring the design.
- Curing: The printed item is heat-cured to set the ink, then inspected and packaged.
What equipment is required for screen printing?
Printing press
Although it’s possible to print manually using just a screen and a squeegee, most printers use a press to improve speed and accuracy. The press holds the screen in place between prints and makes it easier to swap items.
There are three common types:
- Manual – Hand-operated and ideal for small runs or home-based businesses.
- Automatic – Fully mechanized and suitable for high-volume printing with minimal labor.
- Semi-automatic – A mix of manual and automated functions, offering more control with less effort than a fully manual setup.
Large-scale businesses typically use automatic or semi-automatic presses, while smaller operations often choose manual presses for their affordability and control.
Inks
Inks are pushed through the mesh screen to transfer the design. Printers choose inks based on the material, design complexity, and durability needs.
Options include:
- Specialty inks like puff or glitter for 3D effects.
- Heat-resistant inks for fabric durability.
- Washable inks to prevent fading over time.
The right ink must match both the fabric type and the curing process.
Silk screen
The screen is a frame – usually wood or metal – covered with fine mesh fabric. Though originally made from silk, most modern screens use polyester. The mesh texture and thickness vary depending on the design. Once coated in emulsion, the screen acts as a stencil. After use, it’s washed and reused.
Squeegee
A squeegee is a rubber blade attached to a wooden or metal handle. It pushes ink across the screen and through the stencil. Firm squeegees are best for detailed prints, while soft squeegees work well for bold, less intricate designs.
Matching the squeegee size to the stencil helps maintain even coverage.
Washing station
After printing, screens are cleaned to remove leftover emulsion. Large operations use tubs with cleaning solutions or specialized acids, and smaller setups often use water troughs or pressure hoses.
Proper washing allows the screen to be reused and helps maintain stencil clarity for future prints.
Difference between screen printing and DTG
Direct-to-garment (DTG) printing uses a specialized fabric printer, similar to an inkjet printer, to print designs directly onto clothing. Unlike screen printing, DTG does not use a stencil. The printer applies all colors at once, and the ink soaks into the fibers of the garment, creating a smooth, flat finish.
Key differences:
- Setup time – DTG requires little to no setup, while screen printing needs stencil preparation.
- Color and vibrancy – Screen printing produces bolder, more vivid colors, while DTG uses CMYK dots, which can look less intense.
- Texture – Screen printing can create raised or textured effects, but DTG produces a smooth, flat finish.
- Best use cases – DTG is ideal for small orders or designs with many colors, while screen printing is better for large, high-resolution runs and long-lasting prints.
Difference between screen printing and heat transfer printing
Heat transfer printing is any printing method that uses heat to bond a design to a surface. The design is first printed onto a special transfer sheet (such as sublimation paper) coated with heat-reactive adhesive. When heat and pressure are applied, the design transfers from the sheet onto the fabric.
Key differences:
- Technique – Heat transfer applies pre-printed designs with heat and pressure, while screen printing uses a stencil to apply ink directly to the surface.
- Design detail – Heat transfer can reproduce complex, photographic images that screen printing cannot match in detail.
- Customization – Heat transfer is ideal for small batches and personalized prints.
- Quality – The durability and finish depend heavily on the quality of transfer materials and inks used.
- Hybrid options – Heat transfer can be combined with screen printing for extra durable results.
How much does a screen printing machine cost?
Screen printing machine costs vary widely depending on type, automation level, and production needs.
| Machine type | Typical price range |
| DIY kits / Basic manual setup | $150–$500 – Ideal for hobbyists and home-based businesses. |
| Multi-color manual presses | $500–$3,000 – Great for small startups with higher volume and multi-color needs. |
| Semi-automatic presses | $3,000–$20,000 – Offers partial automation and increased output, popular with growing shops. |
| Fully automatic presses | $20,000–$50,000+ – Optimized for high-volume production and efficient workflow in professional environments. |
Why price differences matter:
- Manual presses offer flexibility and affordability for lower-volume operations.
- Automatic systems invest more upfront but significantly boost efficiency, making them a long-term asset for growth.
In practice, many entrepreneurs opt to partner with external print providers rather than purchase costly equipment outright, especially during startup phases.
FAQs
Screen printing on shirts is a fabric decoration method where ink is pressed through a stencil on a mesh screen to transfer a design onto the garments, creating vibrant and durable prints.
Common screen printing types include:
- Spot color printing – Uses solid, vibrant colors for bold designs.
- Halftone printing – Creates gradients or shading with tiny dots of ink.
- Grayscale printing – A form of halftone printing using black ink to produce black-and-white images.
- Duotone printing – Combines two halftone colors to add depth and tonal variation.
- Specialty printing – Includes puff, metallic, glitter, or glow-in-the-dark inks for unique effects.
Screen printing works on many materials, including cotton, polyester, fabric blends, paper, cardboard, glass, wood, metal, and certain plastics – provided the correct type of ink is used for each surface.