Screen printing is done in several different ways, but each involves the same basic technique. The method shown below uses a special photosensitive emulsion to create a custom stencil. Because it can also be used to create complex stencils.
Step 1: Create a plan
To begin with, the printing house takes the template containing the text and/or image elements to be printed on the finished product and prints it onto a transparent film. This will be used to create the stencil.
Step 2: Preparing the mesh
This is followed by selecting the mesh to be used that matches the complexity of the design and the text to be printed. Before applying the photosensitive emulsion layer, the cleanliness of the mesh is checked to ensure the correct printing result.
Step 3: Applying the emulsion and exposing it
The light-sensitive emulsion is applied, then the film containing the design is placed on the coated mesh
and the whole is illuminated. After exposing the screen for a certain period of time, the areas that receive light harden. The emulsion that remains liquid is washed away. This makes the stencil permeable to paint.
Next is drying, then the printer makes any necessary corrections to make the print as accurate as possible. Then the stencil is ready for use.
If multiple colors have to be printed on the substrate or workpiece, a separate screen must be used to apply each ink layer. To create multi-colored products, the printer's expertise is needed to design individual stencils. They must be perfectly compiled so that the end result is the right print.
Step 4: Preparations for printing
The screen is then transferred to the printing press. The workpiece or textile to be printed is placed on the printing plate, under the screen.
There are many different screen printing machines, including manual and automatic equipments, but textile, e.g. in the case of t-shirt printing, is used in most cases a so-called carousel printer. As this allows several different screens to operate simultaneously. In the case of multi-color prints, this type of printer can also be used to apply layers of separate colors in quick succession.
Step 5: Printing
During screen printing, the screen descends onto the printing plate. The ink is added to the upper end,
and with the help of a squeegee, it is pulled along the entire length of the screen. This pushes the ink through the open areas of the stencil, creating the pattern.
If several pieces need to be printed, the screen is raised and a new workpiece is placed onto the printing plate. Then the process is repeated.
Step 6: Drying, check and finish
The printed product then goes through the drying process so that the surface reaches the resistance expected during use. The final product is then checked and packaged before being handed over to the customer.
Step 7: Screen cleaning
After all items have been printed, the emulsion is removed with a special washing liquid. This way, the screen can be used again to create new stencils.
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