Screen Plate Making
Screen plate making is the process of forming the design areas that allow ink to pass and the areas that do not on a screen printing plate, in order to print patterns accurately onto fabric.
Contents6 sections
Definition and Overview
Screen plate making is the process of creating the areas through which the pattern passes on mesh stretched on a screen frame, using photosensitive materials and similar methods based on design data. The finished plate is used when printing ink onto fabric by screen printing.
As a general rule, a separate plate is prepared for each color, so the number of plates increases for multicolor patterns. To reproduce lines, text, and fine patterns, it is important to manage the way the data is prepared and the precision of the plate together.
Factors That Affect the Finish
The fineness of the plate mesh, the line width of the pattern, the properties of the ink, and the surface condition of the fabric affect print outlines, color development, and how the ink sits. On fabrics with coarse weave, fuzz, or uneven surfaces, detailed expression may be difficult.
Screen plate making itself is not a process that determines the texture or functionality of the fabric. However, the texture after printing changes in hardness, thickness, and the feel of breathability depending on the type of ink, ink amount, and curing conditions.
- For fine lines and small text, confirm a size that will not cause filling in or fading.
- For multiple colors, misalignment between colors is more noticeable, so consider registration.
- For photographic or tonal expression, confirm the reproducibility of halftone dots in advance.
Main Applications
Screen plate making is used for screen printing on T-shirts, sweatshirts, shirts, bags, uniforms, and promotional textiles. It is used as a suitable method for projects that repeatedly produce the same pattern.
It is used throughout the year, but the comfort and durability required differ by item. For clothing that touches the skin, check not only the pattern expression but also the hardness of the printed area and its ability to follow stretch.
Notes for Submission and Production
When submitting artwork, clarify the number of colors used, color specifications, pattern dimensions, print position, pattern repeat, and whether text needs to be outlined. Depending on the effect of the fabric color and whether a base ink is used, the expected color and appearance may change.
Cracking, peeling, color fading, and dye transfer after washing are related not only to the plate but also to the combination of ink, fabric, pretreatment, and drying and curing conditions. Before full production, it is important to make a sample on the actual fabric and confirm it, including washing tests.
With highly stretchy knits or fabrics with surface finishes such as water-repellent treatment, attention is needed for ink adhesion and stretch followability. When adding a pattern after sewing, also consider missing areas and misalignment caused by seams and steps.
Differences from Similar Terms
Screen plate making is the process of making the plate, while screen printing is the process of using that plate to print a pattern onto fabric. Printing is a broad general term and also includes methods other than screen printing, such as inkjet and transfer printing.
Rotary screen printing is a method that prints by continuously rotating a cylindrical plate. It differs in plate shape and production method from hand screen printing and automatic screen printing that use flat plates.
Frequently Asked Questions
Is a plate needed for each color in screen plate making?
In general screen printing, a plate that allows ink to pass is prepared for each color. Therefore, as the number of colors increases, the number of screen plate making tasks, registration adjustments, and prototype checks also increases. For designs that include blurs or tonal gradations, it is best to discuss the expression method in advance.
Can fine text and lines also be reproduced with screen plate making?
Reproduction is possible, but there are limits depending on line width, text size, mesh, ink, and the condition of the fabric surface. Fine details may be filled in by ink or have unclear outlines, so readability and gaps are checked with a test print at actual size.
Is screen plate making the cause of cracking in printed items after washing?
Plate precision may affect it in some cases, but cracking can occur due to multiple factors such as ink selection, application amount, insufficient curing, fabric stretch, and washing conditions. It is necessary to select inks and processing conditions suited to the application and to carry out washing tests before mass production.
