Common Screen Printing Problems and How to Solve Them

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Screen printing can be a rewarding and creative experience, but it can also be filled with unexpected problems and setbacks.

From print registration issues to ink fading and poor adhesion, there are a number of common problems that can occur with screen printing which can make the process difficult.

So what do you do when these common screen printing issues arise? That’s where this guide comes in. In this article, we’ll be looking at some of the most common screen printing problems and how to solve them. We’ll be covering topics such as how to troubleshoot misaligned prints, why your ink is fading, and how to prevent poor adhesion.

Choosing the Wrong Ink Color

Choosing an incorrect ink color is a common mistake, and can originate from both the printer and the customer. As a customer, it’s important to ensure that you’re providing accurate colors for your project so your desired results are achieved. As a printer, you should double-check colors to guarantee they are correct before going ahead with the job.

If you accidentally use the wrong color, there are three possible solutions:

Use a solvent-based product to remove the ink and start again from scratch.
Overlay with an additional layer of ink that is closer to the desired color
Heat-set multiple layers of matching colors until it meets what was requested.

Whenever any of these methods are used, it’s important to test them on scrap fabric before proceeding as some fabrics may be damaged by solvents or multiple layers of heat setting.

Poor Print Coverage or No Image at All

Poor print coverage or no image at all can happen when the screen isn’t properly prepared. This generally happens when there’s too much tension on the screen mesh, or if there’s a buildup of ink on the substrate.

Here are some steps to take to solve this problem:

Check that your mesh is properly stretched and free of any excess tension, wrinkles, or tears.
Make sure you’re using the right mesh count for your project.
Make sure your stencil is completely dry and free of streaks before printing.
Use a squeegee with proper pressure and angle relative to the stencil so that it doesn’t miss any spots.
Thoroughly clean the print area after each job to avoid clogging the mesh with old ink residue.
Make sure all stencils are completely cured and that photopolymer emulsions are completely exposed before printing onto them.

Inks Smearing or Blurring

We all know that dreaded feeling of seeing your ink smeared or blurred after creating a work of art. Whether you are a beginner or a master, this is an issue all screen printers experience.

Thankfully, there are easy and effective solutions to this issue:

Change the ink consistency – Adjusting the viscosity of your screen printing ink can make a world of difference when it comes to smearing and blurring. Experiment with different ratios until you achieve the desired result.
Thin out with retarder – If you are looking for a more precise adjustment, adding retarder to thin out your ink can give you greater control over its viscosity.
Check for adhesion issues – Sometimes the culprit behind smeared and blurred prints is not the ink itself; poor adhesion can cause this problem as well. Adhesion issues are often caused by improper surface preparation or an unsuitable pressing surface on the garment, so make sure these pieces are in place for optimal results.
Adjust exposure time – The exposure time plays an important role in preventing smearing and blurring, so adjust it accordingly based on your type of emulsion and exposure unit being used.

Don’t let smeared or blurred prints ruin your day! Follow these simple steps to solve this common screen printing problem and ensure a clear, crisp print every time.

Ink Fading or Cracking

The majority of printed items experience some degree of fading or cracking, but the amount of impact on your design depends on the type of ink used. Fortunately, there are several solutions available to help you avoid faded or cracked prints.

Selecting the Right Ink

Selecting the right type of ink for your project can make a huge difference in the overall quality and longevity of your design. Generally, solvent-based inks are more durable than water-based inks, as solvents are less prone to absorbing moisture from the air. It is important to consider both the type and quality of ink that you use in order to achieve prints with maximum vibrancy and durability.

Applying a Layer of Varnish

Applying a layer of varnish over screen prints is an effective way to increase durability and vibrancy as well as protect against fading or cracking. Look for a high-quality varnish with UV protection to guard against any damage caused by sunlight exposure.

By taking these steps, you can ensure that your designs stay vibrant for years – no matter what kind of conditions they’re exposed to!

Inconsistent Image Quality Across Different Shirts

One of the most annoying issues with screen printing is that image quality can vary across different shirts. This can be due to a number of factors: uneven dye coverage, incorrect temperature regulation, or even environmental conditions such as humidity and air temperature.

The key to ensuring consistent image quality across all shirts is preparation. Here are some tips to prevent this issue from occurring:

Use high-quality screens and keep them clean and dust-free to avoid debris from affecting print quality.
After coating your screens, store them at room temperature in a dust-free environment until ready for use.
Check that your artwork is at the right resolution before printing – artwork that is too low resolution will cause images to appear blurry when printed on fabric.
Use a good quality plastisol ink to ensure even coverage and even curing of prints over different fabrics – this helps maintain consistency while printing on a variety of garments.
Overprinting your design onto a lower count fabric will help with coverage, while giving you more time for curing the prints evenly over different types of fabrics .
Check screen tension regularly on each job – too tight or too loose tension can lead to inconsistent image quality across different shirts .
Ensure proper curing temperatures for both fabric and ink – this will help maintain consistent print results across different types of materials being printed .

Issues With Stencil Making and Registration

Stencil creation and registration are two of the trickiest parts of the screen printing process. Without these two components being carefully managed, the finished product can be different than expected, or even unusable.

Stencil Making

Stencils are used to transfer ink onto the substrate, so they must be made with accuracy and attention to detail. When creating a stencil, you must use the correct mesh size for your design requirements and make sure there is enough pressure between the frame and fabric. It’s also important that you check for any flaws in the screen before using it, as any imperfections will affect the print quality.

Registration

Registration refers to how precisely an image is placed on a substrate in relation to its intended position. Inaccurate registration can lead to blurred or distorted images, while too much movement can cause smearing or double printing. To ensure accuracy during registration, use magnets or clamps to secure your substrate in its proper place while you print. It’s also important to use a high-quality squeegee and adjust tension settings if necessary.

Conclusion

Despite the challenges that screen printing can bring, the results can be incredibly rewarding. By taking into consideration the above-mentioned tips and tricks, screen printing can be a quality and cost-efficient printing method. As a principle, it should be remembered that improving the process, rather than changing it, is the best way to maximize the potential that screen printing has to offer. With the right tools, set-up, and knowledge, you will be able to produce prints that stand out, remain durable, and are cost-effective.