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• SCREEN PRINTING PROCESS •

PUFF INK

This is usually gray but can also come in other colors. The ink contains glass beads that reflect light. This ink is now offered in a Plastisol base so it is now more opaque than in the past. Artwork should be spot colors so that a lower mesh can be used.

PUFF INK

This is an additive that can make any color ink puff (raise off the garment) when sent through the dryer. You can vary the percentage (no more than 10%) of additive to affect the height of the print. Artwork should be spot colors because a very low screen mesh (60-86) has to be used.

GEL

Gel is a process that makes clear, shiny layer on top of regular Plastisol ink or can be printed on top of a process print to reduce the appearance of individual dots in the print and keep the print from fading. It is relatively simple and requires no special screen or printing process.

METALLIC INK

Metallic ink is a simply a Plastisol ink whit small bits of a reflective type metal in it that make the entire print area take on a metal or shiny look. It is relatively consistent in its effect (unlike glitter). Metallic inks come in special colors only and can't be mixed into other colors. Artwork requirements for this process are spot color prints in which a low mesh (60-86) screen can be used.

GLOW IN THE DARK INK

Glow in the dark ink contains a phosphorus compound that, when "charged" by exposing to a light source emits a relatively bright green yellowish glow when in the dark. This process needs an underlay of white ink because the glow ink has no pigment and is usually used on black shirts. Artwork restrictions are few. Glow in the dark can be printed through a 155-mesh screen.

COMBINATION OF PROCESSES

We can also use some combinations of processes to achieve a unique effect for your print. Some examples of this are using puff ink with metallic or glitter on top of it. Ask us about the possibilities of using other combinations.

FAUX EMBROIDERY

This is a process that makes a printed graphic look embroidered (at least from 3 or 4 feet away). It is done using artwork modifications and printing a layer of puff ink as an underlay so the graphic will have some texture off the garment.

FOUR COLOR PROCESS (Illustrator & Photoshop)

We can print four-color process graphics and garments a couple of different ways. Depending on the artwork, they are set up in one of two graphics programs. Four-color process on a garment differs substantially from 4pc on paper. We cannot hold the fine detail that offset printing demands. We usually use about a 45-55 line screen on process graphic (which makes the dots much larger). The colors mix well using process inks, but due to dot gain (dots smearing together) in screen printing you should expect a little variation in the colors from your original. This process is good for graphics that are multicolor and not so color specific like hand drawn illustrations or reproductions of paintings (without flesh tones). We must use high mesh counts (305 or 355) to hold the dots so that the colors will mix properly.

SIMULATED PROCESS (Spot Process or Manual Seps)

Simulated process is for graphics that require precision in color matching but are detailed or halftone oriented graphics. In this process the graphic is separated into a six to 12 color process file then specific colors are assigned instead of the regular process inks. This makes the main colors in the graphic match better while still allowing some inks to mix and make other colors. This process is good for photo replication (with flesh tones) and detail oriented graphics. We must use high mesh screens on this process as well.

PRINTING ON NYLON OR SATIN FABRIC

We are able to print on nylon, mesh and satin fabrics using an additive to regular Plastisol ink called nylobond. This additive enables the ink to stick to the fabric better to reduce the chance of the ink peeling off the garment. It is usually a slow process in production because every layer of ink has to be flashed before the next layer is printed. We can print on mesh garments as well but the artwork needs to be spot colors with no small details that can be lost in the "wells" (holes) of the garment.

SPECIAL PLASTISOL ADDITIVES (Suede, Clear, HD, Roc-Base, etc.)

We are using some additives now to mix custom colors and processes for various graphics. The artwork can be specially modified for these processes or we can incorporate them into existing art.

Screen printing processes and technology are constantly changing so keep in mind that you can achieve a unique look by using a special process on your garment. F&E Sportswear will stay up to date on a new processes and continue to perfect the processes we use.