Module 1

Welcome to Module One! In this module, you’ll gain a deeper understanding of the screen printing process and its importance in creating high-quality custom designs. Whether you explain the process to customers or assist with orders, knowing these steps will help you communicate clearly and build customer confidence in your work.

By the end of this module, learners will be able to:

Describe the key steps in the screen printing process. This includes film development, screen preparation, press setup, printing, and drying. CO1
Describe Print Masters’ unique screen printing workflow and how it ensures consistency in the final products. CO1

The Screen Print Process

Welcome to this brief overview of the screen printing process. Today, we’ll walk through the essential steps involved in creating a high-quality screen-printed garment, from developing films to drying the final product. By understanding each phase, you’ll gain insight into the care and precision required for screen printing.

1. Developing Films:

The process begins with design preparation, where the artwork is separated by color, as each color requires its own screen. These color separations are printed onto transparent films, which act as stencils for the screens. The film blocks light in specific areas, creating a template for where the ink will pass through during printing. This step is critical because any errors in the film will directly affect the final design.

2. Preparing the Screens:

Once the films are ready, we move to screen preparation:

A mesh screen is coated evenly with a layer of photosensitive emulsion, which hardens when exposed to UV light.
The transparent film is placed on the screen, and the screen is exposed to UV light. The areas blocked by the film remain soft, while the exposed areas harden.
After exposure, the screen is washed out with water. This removes the soft emulsion, leaving a stencil of the design on the screen. Each screen corresponds to one color in the design, so this step is repeated for every color layer.

3. Preparing the Press

With the screens ready, the next step is to set up the screen printing press:

Each screen is aligned carefully on the press to ensure the design prints accurately when multiple colors are used. This process is called registration and ensures that all colors line up perfectly.
The press is then calibrated for the specific garment being printed, such as a t-shirt, hoodie, or tote bag.

4. Running the Print Job

Now it’s time to apply the design to the garment:

The garment is placed on the printing platen, which holds it in place during the process.
Ink is applied to the screen, and a squeegee is used to push the ink through the open areas of the screen and onto the garment. This step is repeated for each color in the design, with each screen applied in sequence.
After each layer of ink is applied, the garment is carefully inspected to ensure quality and consistency.

5. Drying the Garment

Once the printing is complete, the garment moves to the drying phase:

The printed item is sent through a conveyor dryer, where high heat cures the ink. This ensures the design adheres to the fabric and remains durable through washing and wear.
After curing, the garment is inspected one last time for quality assurance, ensuring the print is vibrant, aligned, and free from imperfections.

Films

Preparing the Screen and coating it with light sensitive emulsion.

Prepare the Screen

Preparing the press and pouring ink onto the screen.

Prepare the Press

Employees running a print job on the press.

Run the Job

Shirts being sent through a conveyor dryer, where high heat cures the ink of the shirts.

Dry

Projects

Screen Printing 101

Please watch the short video about the screen printing process, and then complete the brief knowledge check at the end. (5 points)

Print Masters Workflow

At Print Masters, we follow a structured workflow to ensure every order is processed smoothly while also meeting our high expectations. Here's a brief overview of our process:

1. Request a Quote

Customers start by requesting a quote for their order. This includes details such as product type, quantities, and any customizations or design specifications. We will practice collecting order details and generating quotes later is this training.

2. Review & Approve the Quote

Once the quote is prepared, it’s sent to the customer for review. Customers carefully check the details and approve the quote to move forward with the next step in our process.

3. Art Development

Customers either submit their own design files or work with our team for artwork development. Once the artwork is finalized, proofs are created for customer approval to ensure the design meets their expectations.

4. Pay 50% Deposit

To begin production, customers must pay a 50% deposit. This secures their order and confirms all specifications.

5. Order Production

Once the deposit is received, the order enters production. Our team carefully follows the approved artwork and order details to create high-quality prints.

6. Pay Balance & Pick Up Order

When the order is complete, the customer will pay the remaining balance. Orders can either be picked up or shipped shipped directly to them, depending on the customer’s preference.

A quick note about Production time:

In most cases, there is a minimum of 10 to 14 business day from the day you approve your artwork (and we have your 50% deposit) to the day it’s ready to be picked up or shipped. Rush orders may sometimes be approved, for a fee, at our discretion.

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Module 2