Screen preparation

Nahida Akter
Assistant Professor
DTE, AUST
 Screen printing

 Screen printing is a printing technique in which a woven mesh

is used to support an attached stencil. The attached stencil is
created to form open areas of mesh through which the ink
may travel and closed areas blocking the transfer of ink to the
substrate below. The ink is placed on the upper side of the
screen mesh and a squeegee is used to move the ink across
the screen and through the open areas of mesh. The ink that
passes through the screen is deposited onto the substrate. The
ink is then cured using either air, heat or both, until it has
adhered to the substrate and created a permanent or semi
permanent bond.
Screen printing
 Screen printing

 Screen printing is used to print on different types of items, such as technical

textiles, textiles for clothing and footwear, leather goods, furnishing,
household and decorative textiles.
 Moreover, the printed surface can be made of paper, cardboard,
polymeric materials, wood, metal, leather and non-woven substitutes.
Factors that determine the quality of the
screen printing process
 mesh type (PET, PA);
 mesh color;
 mesh density (counted thread/cm);
 thread diameter;
 mesh stretching angle;
 raster density;
 raster angle;
 ink viscosity;
 print speed;
 squeegee angle;
 take of distance.
 Screen printing
The factors that determine the quality of the screen printing process are
 mesh type (PET, PA);

Polyamide
 good mechanical durability
 very good mechanical durability
 good abrasion resistance
 high abrasion resistance
 high resistance to stretching
 good surface-tension
(Fixed-frame screens will slowly lose tension
during the printing process and subsequent characteristics
cleaning and reclaiming procedures. Over  high elasticity
time, the screen will lose enough tension that
achieving consistently good prints using  Good dimensional recover
proper setup techniques no longer will be.) characteristics
 high resistance to light
 insensitivity to climatic factors
(temperature and humidity)
Surface energy
Compare between PET and PA

Polyamide (PA) Polyester (PET)

Specific gravity 1.14 1.38
Tensile strength in
daN/mm2 (dry) 41 - 67 45 - 75
Tenacity (wet) % 90 - 95 100
Elongation at break %
- Dry 20 – 35 15 – 30
- wet 25 - 40 15 - 30
Melting point °C 247 - 253 240 - 260
Softening point °C 225 - 235 220 - 240
Compare between PET and PA

Polyamide Polyester
Temperature resistance Colour change Dry heat up to
 C from white to 150°C
yellow. The degree
of change and
strength reduction
depends on the
temperature and
reaction time.
 Compare between PET and PA
Polyamide PA Polyester PET
Resistant to acids Sensitive to acids Highly resistant to
Fibres are either inorganic acids
weakened or destroyed,
depending on
concentration,
temperature and
reaction time.
Resistant to Alkali Good resistance to Sensitive to alkalis
alkalis Fibres can be weakened
to the point of
destruction, depending
on concentration,
temperature and
reaction time.
Resistant to light and Low to average Good to very good
weather
Mesh type description
 W = White
 Y = Yellow
 CY = spun dyed, yellow
 PW = Plain Weave
 TW = Twill Weave
 OSC = One Side Calendered
 PET 1000 = High modulus
monofilament polyester mesh
 PET 1500 = High-modulus mesh,
specially surface treated for good
adhesion
 Mesh Count

 The mesh count refers to the number of threads per inch contained in the mesh.
 Mesh Colour
The factors that determine the quality of the screen printing process are
 mesh color (White mesh vs yellow mesh)
 By exposing a direct stencil to light, the illuminated areas become hardened. Light
rays striking the white fibres of the fabric are reflected, and scatter under the black
edges of the film. Scatter increases with the increase in mesh count and exposure
time.
 Light is also conducted through the fibres themselves, leading to yet more under
cutting. The results are unsharp printed edges, causing colour shifts in multicolour half-
tone artwork. There is a reduction of the open printing areas, particularly in fine detail
work. To keep these phenomena under control, it is necessary to calculate exposure
times leading to proper exposure.
 Mesh Colour
The factors that determine the quality of the screen printing process are
 mesh color;
 White mesh vs yellow mesh
 Mesh Colour
 Emulsions and films are sensitive in the UV range, from approx. 350 to 420 nanometres.
To be effective, light scatter protection must absorb UV light over this wavelength
range.
 When UV light strikes a yellow fibre, only yellow light is reflected and this has no effect
on the emulsion. This is why it is advisable to work with emulsion in yellow light.
Emulsions are sensitive only to blue UV light.
 The results are pin-sharp edges, and open details. exposure times on dyed fabrics are
75% – 125% longer than on their plain white counterparts due to less light scatter of
blue UV light; this results in tougher, more durable stencils.
 Mesh Colour

 Dyed fabrics should always be chosen for printing the finest lines, text and
half tones.
 Mesh Opening

 Mesh opening (w) is the spacing between adjacent warp or weft threads,
and is measured perpendicular to the plane of the fabric.
Mesh opening governs:
 the maximum particle size to be used in a screen printing ink
Mesh opening affects:
 the level of printed detail in line and half-tone artwork
 ink release characteristics
 the thickness of the ink volume
Note: For adequate ink penetration, the average particle size of the screen
printing ink must be smaller than 1/3 of the mesh opening.
 Mesh Opening
 a) Mesh opening greater than thread diameter (ω > d)
PET 1000 150–27PW (ω =36μm)
 b)Mesh opening comparable to thread diameter (ω ≅ d)
PET 1000 150–31PW (ω =32μm)
 c) Mesh opening less than thread diameter (ω < d)
PET 1000 150–34PW (ω =23μm)
 In general, fabrics where the mesh opening is greater than the thread diameter
are capable of higher resolution than fabrics where the opposite is true.
 Next to the relationship of thread diameter to mesh opening, the thread
diameter itself also affects the printable dot / line size.
 Secondary factors in the printability of fine line and half-tone artwork are the
flow, viscosity and rheology of the screen printing
 Thread Diameter

 The thread diameter refers to the diameter of the thread before it has been woven
into the mesh.

Plain weave 380- Plain weave 380- Plain weave 380-

thread/in. mesh thread/in. mesh thread/in. mesh
with 27-micron with 31-micron with 34-micron
thread diameter thread diameter thread diameter
 Thread Diameter
 When mesh count remains unchanged, choosing a smaller filament
diameter opens up the mesh and renders it much less obstructive to ink
flow. This is readily apparent in the representative illustration in Figure 1.
 The increased open area of mesh types with reduced thread diameter at
similar mesh count equates to less filament surface area within the print
cavity. As ink passes through a screen’s print cavities, it is in direct contact
with the threads. By reducing the thread surface area, mesh will release
easier at the moment of ink transfer.
 Thread Diameter

 Smaller diameter thread at the same mesh count creates higher open area
by increasing the size of the mesh apertures. Larger mesh openings allow
for easier transfer of higher viscosity inks, or inks that have relatively larger
particle size or high solids content.

380-thread/in. mesh 380-thread/in. mesh 380-thread/in. mesh

with 27-micron with 31-micron with 34-micron
thread diameter thread diameter thread diameter
 Thread Diameter
 Filament diameter size has the
most influence on mesh
thickness. When the diameter is
reduced, overall mesh
thickness becomes thinner.
Larger thread diameter
increases mesh thickness. As we
can see the smallest filament
diameter indeed provides the
largest mesh aperture size,
providing greater open area.
Fig depicts the reduction in
mesh thickness resulting from
thinner thread diameter. The
red blocks represent the open
columns in the mesh through
which the ink must transfer.
 Thread Diameter
 The taller, chimney-like
column on the right is a result
of a thicker, more closed
mesh, due directly to a larger
diameter at similar mesh
count. The increased thread-
surface area, taller mesh, and
smaller opening size make for
more difficult ink flow and
transfer from screen to
substrate.
Photographic image printing
 Mesh Stretching Angle

• The concept of the angle of the stretcher refers to the angle formed by the warp
and weft (wire) of the screen and the edge of the frame.

• There are two forms of stretch nets, one is a stretch net and the other is a
diagonal stretch net.

• The positive stretch net is that the warp and weft of the screen are parallel
and perpendicular to the four sides of the frame. That is, the warp, weft and
the frame edge are 90 degrees.

• The skewed stretch net means that the warp and weft of the screen are at an
angle to the four sides of the frame.
 Mesh Stretching Angle

• The screen printing is prone to moiré in the form of

screen printing, so the color printing usually does not
use the positive stretching net. The use of oblique
meshing is beneficial to improve the printing quality,
and it also has a certain effect on increasing the amount
of ink leakage. The disadvantage is that the screen waste
is large.

• In the printing precision requirements and color printing,

the choice of the angle of the stretch screen has a direct
impact on the printing quality. Therefore, the printing
angle of the general replica is usually 20 degrees to 35
degrees.
 Mesh Stretching Angle

 Instrumental set up
 Ink Viscosity

 Rheology is the study of the properties and behavior of fluids, specifically how
they flow and react to pressure. In screen printing it means print paste viscosity.
 Viscosity is how a liquid flows. Liquids with low viscosity flow quite easily; liquids
with high viscosity are thick and tend to stay put. Viscosity can change by
varying the amount and type of thickener.
 Probably no other single characteristic influences how ink prints as much as its
viscosity.
 Ideal Screen Printing inks/pastes are non Newtonian fluids with pseudoplastic
(shear thinning) and thixotropic (viscosity decreases over shear time) properties.
This provides good ink transfer with the ink only flowing when sheared by the
squeegee and minimal spreading once printed. This occurs since the ink’s
viscosity reduces when sheared, but starts to increase again once the source of
shear stress is removed.
 Ink Viscosity
Provides good ink transfer with the ink only flowing when sheared by the squeegee and
minimal spreading once printed. This occurs since the ink’s viscosity reduces when
sheared, but starts to increase again once the source of shear stress is removed.
 Ink Viscosity
 The viscosity is the most important rheological characteristics of the conducting paste.
 The conducting paste for screen printing process should show the pseudoplastic behavior
which displays a decreasing viscosity with an increasing shear rate.
 However, to be suitable for screen printing, conducting paste should be somewhat
thixotropic in nature. A thixotropic fluid is one in which the shear rate/shear stress ratio is
nonlinear.
 As the shear rate (which translates to the combination of squeegee pressure, velocity, and
screen tension) is increased, the paste becomes substantially thinner, causing it to flow
more readily.
 The optimum operating viscosity of the paste is dependent on the parameters with the
screen printing process. The variations in squeegee speed, squeegee to screen angle,
squeegee pressure and snap-off distances will affects the quality of the printed film.
 If the printed lines have a tendency to spread on standing, it is likely that the viscosity of
the paste is too low. The paste viscosity is a significant factor to control the line width
including the thickness and roughness of the printed pattern. The paste viscosity is too high
if the printed films display mesh marking, pinholes or very thin areas covered with paste.
 Squeegee Angle

 In screen printing, the angle formed

between the face of the blade of
the squeegee (the side of the blade facing
in the direction of the printing stroke) and
the plane of the screen. The squeegee
angle is measured with the squeegee in
printing position, but not under printing
pressure. A similar measurement, but with a
different value due to the flexibility of the
rubber squeegee blade, is the angle of
attack or printing angle, or the angle formed
by the face of the squeegee blade when
under printing pressure.
 Squeegee Angle
 Squeegee is a device that is a rubber spatula with which the ink is forced
through the mesh stencil.
 Changing this angle changes the amount of ink is pressed through the
mesh. The smaller the print angle the greater the amount of print paste will
go through the mesh. At an angle greater than 90 ° count ink squeezes
through the screen theoretically zero. The optimum is considered to yield
an angle of 75 ° from the screen. Large deviation from this angle can
adversely affect ink control and register of the print.
 Print Speed
 Print speed must be keep the maximum print speed to ensure performance
of the printed area. The rate affects the viscosity. The higher the viscosity,
the lower the print speed and high probability of ascent squeegee on the
paint. So you need to install more squeegee pressure.
 Take off distance
 Off contact is the distance between the
bottom of the screen mesh and the top of
the garment being printed. Off contact
distance typically varies from 1/32" to
about 1/4" inch depending on the
following factors
 Type of garment are printing on
 The type of ink are using.
 The type of screens you are using (metal,
plastic or wood). Wood tends to have less
tension so you will need a bigger Snap Off
than with a high-tension metal screen.
 Take off distance
 Using more off contact also increases the
amount of ink deposited on the t-shirt.
Decreasing and using a smaller off contact
distance reduces the amount of ink
deposited on the shirt. But off contact also
helps control the crispness of our prints- while
also reducing ink build-up on the backs of
screens when printing wet on wet.
 For clean prints with accuate register and
perfect print image, correct settings of the
snap- and lift-off distances are very
important.
 Take off distance
 Discharge and water base ink usually use
1/32" of an inch for off contact- equal to
the thickness of a dime. Off contact for
printing plastisol ink is usually 1/6" of an
inch- equal to the thickness of a quarter.
Use a little more than a quarter (two
quarters) for printing hoodies and
sweatshirts.
 First, the type of substrate to be printed.
Second, the type of screens you are using
(metal, plastic or wood). Wood tends to
have less tension so you will need a bigger
Snap Off than with a high-tension metal
screen.
 Geometry of screen printing fabric
The basic factors in fabric geometry are mesh count and thread diameter.
Fabric geometry directly affects:
 printability of fine line and half-tone images
 edge definition in the print
 ink release characteristics
 maximum printing speed (in conjunction with ink viscosity)
 thickness of the ink volume
 ink consumption
 ink drying
 Geometry of screen printing fabric
The following values, listed in technical datasheets, such as
 mesh opening in μm, abbreviated to (w)
 mesh opening in %, abbreviated to (ao)
 mesh thickness (fabric thickness) in μm, abbreviated to (D)
 theoretical ink volume in cm3/m2, abbreviated to (Vth)
are all derived from the mesh count (Fn) and the thread diameter (d).
 The fundamental geometrical unit is the fabric pitch (t).
Pitch (t) is the sum of one mesh opening and thread diameter (t = w + d).
Open area, o (open mesh area in %)
 The sum of all the mesh openings over the total area. A fabric with an o of 30.5%
has an open mesh area of 30.5%, and a closed, impervious area of 69.5%.
 o % is one of the variables used to calculate the theoretical ink volume.
 Geometry of screen printing fabric
 Theoretical ink volume Vth (cm3/m2)
 This value is calculated from the open area and
mesh thickness. The volume of the open mesh
governs the effective amount of ink that a
screen printing fabric can accept. The
calculated effective ink volume is higher than,
but proportional to, the theoretical ink volume.
 Under realistic conditions, the degree to which
a fabric is filled with ink depends on the
squeegee speed, squeegee blade
characteristics – hardness, angle, and finish and
the consistency of the ink itself.
 Geometry of screen printing fabric

Basic ink consumption Mf is then estimated by: m2/Lt = 1000/ Vth

 Compensation
Compensation factor S for porosity of the printing stock: factors for ink thinning
 S for highly porous printing stock = 0.5 percentage (V)
 S for slightly porous printing stock = 0.8
 V 0% = 1
 S for non-porous printing stock = 1.0
 V 5% = 1.05
Taking all these factors into account, the approximate ink
consumption Mf can be derived from the screen printing fabric’s  V 10% = 1.10
theoretical ink volume using the following formula:
 V 15% = 1.15
 m2/Lt = (theoretical coverage) * S * V
𝟏𝟎𝟎𝟎
 V 20% = 1.20
 = 𝑽𝒕𝒉∗𝑺∗𝑽
 Problem
Imagine you have an order to print 1000 meter woven fabric using pigment. For this
screen printing order you choose PET 1000 150-34Y PW mesh fabric with 23  and 54 
mesh opening and mesh fabric thickness respectively. Now determine the
approximate print paste consumption for this order.
[Assume S is slightly porous printing paste with V10%].