Screen Printing

Screen printing forces ink through a mesh stencil (screen) onto the fabric surface. Each color requires its own screen, making it cost-effective for high-volume runs with a limited number of spot colors.

We offer both flat-bed screen printing for cut-and-sew panels and rotary screen printing for continuous yardage.

Process Overview

1. 1
   A separate screen (stencil) is created for each color in the design
2. 2
   Ink is pushed through each screen onto the fabric in sequence
3. 3
   Colors are aligned precisely to avoid mis-registration
4. 4
   The printed fabric passes through a heat tunnel to cure the ink

File Requirements

• Accepted formats: PDF, PSD, AI
• Minimum resolution: 300 DPI at final print dimensions
• Colors should be specified in Pantone (PMS) for accurate matching
• Separate layers for each color are recommended

Advantages

• Cost-effective for runs of 50+ units per colorway
• Bold, opaque ink — prints well on both light and dark fabrics
• Pantone-matched colors for precise brand consistency
• Extremely durable — industrial ink holds up to heavy commercial use
• Works on cotton, canvas, denim, blended fabrics, and more

Limitations

• Screen setup cost: approximately $40 per color/screen
• Maximum of 12 colors per design
• Design changes require new screens — add-on cost for revisions
• Photorealistic gradients and photographic images are not achievable
• Ink layer adds slight texture to the fabric hand

Rotary Screen Printing

For continuous fabric yardage, we use rotary screen printing where cylindrical screens rotate as fabric feeds through — enabling seamless repeat patterns at scale.

• Minimum: 1,000 meters for woven fabrics or 500 kg for knitted fabrics
• Ideal for all-over patterns, stripes, and repeat motifs
• Same color and file requirements as flat-bed screen printing