Common process classifications for screen printing

As an ancient and widely used printing process, screen printing still plays an important role in many fields, especially in the textile, clothing, advertising, and other industries. After years of development, screen printing technology has been innovated in equipment and materials and refined into many different process categories, each with its characteristics for different needs, materials, and effects. This article will deeply analyze the common process classification of screen printing to help readers better understand this widely used printing technology.

 The basic principle of screen printing

Before we delve into the process classification, we first need to understand the basic principles of screen printing. Screen printing is a process whereby ink or printing paste is squeezed through the mesh of the screen by a scraper or other means and transferred to the surface of the substrate. The part of the screen that does not need to be permeable to ink is masked, while the part that needs to be printed remains transparent so that the ink can transfer the pattern to the material through this part.

This process is suitable for various materials, including textiles, paper, metal, plastic, glass, etc., so it is widely used in different fields. A notable feature of screen printing is that the printing has a strong sense of layering and bright colors, which is suitable for large-area printing and mass production.

Standard process classification of screen printing

Screen printing can be divided into many processes, depending on the materials, printing methods, and effects. The following are some standard screen printing process classifications and their characteristics.

     1. Rubber Printing

Rubber Printing is one of the most common screen printing processes and is often used for clothing printing, especially cotton fabrics. Glue is a resin-based material with strong hiding power and adhesion, making it very suitable for dark fabrics. By printing the glue onto the fabric through the screen, the pattern can remain transparent, color-saturated, and have a specific three-dimensional effect.

Advantages of Rubber Printing:

The Rubber Printing is brightly colored and suitable for dark fabrics; its pattern surface is glossy and suitable for large-area printing; it is also washable, and the pattern does not quickly fade or fall off.

Disadvantages of Rubber Printing:

(1) The surface of the Rubber Printing pattern is relatively complex, which may affect the softness and breathability of the fabric. The main reasons are as follows:

① Paste printing usually uses resin or synthetic glue as a binder to fix the pigment on the fabric. After drying, this binder will form a thin film on the fabric's surface. Compared with the fiber structure of the fabric itself, this film is usually more complex and thicker.

② Due to the presence of this film, the feel of the printed pattern part of the adhesive printing will be significantly different from that of the unprinted fabric part, and it will appear stiffer. This difference is pronounced when touching, which may reduce the comfort of wearing, especially for clothes that pursue a soft touch, such as underwear, baby clothes, etc.

③. Also, due to the barrier effect of the film, the air permeability of the Rubber Printing pattern area will be affected to a certain extent. This effect may be more obvious in hot or humid environments, causing the wearer to feel stuffy and uncomfortable.

(2) Rubber Printing is not suitable for thin fabrics

① Increased weight and thickness: As mentioned above, adhesive printing will form an extra film on the fabric's surface, which will naturally increase the weight and thickness of the fabric. For the initially light and thin fabric, this increase may destroy its original lightness and flowing feeling, greatly reducing the overall visual effect and wearing experience.

② Limited detail expression: Light and thin fabrics often have higher requirements for detail expression because they are more likely to show delicate textures and textures. However, due to its material properties and process limitations, Rubber Printing may make it challenging to achieve delicate patterns and color transitions on light and thin fabrics, thus affecting the final design effect.

③ Increased fragility: Light and thin fabrics are usually fragile and easily damaged during washing or wearing. Although the film formed by adhesive printing increases the wear resistance of the fabric to a certain extent, it may also make the fabric more prone to cracking or peeling when subjected to external forces, thereby shortening the service life of the clothing.

     2. Water slurry printing

Water slurry printing is more environmentally friendly and mainly used for light-colored fabrics. Water slurry is a water-based printing slurry. Unlike rubber , it does not have strong covering power, so it is usually used for light-colored or white fabrics. The pattern of water slurry printing is relatively soft and feels good, which is suitable for clothing printing with high requirements for pattern texture.

 

Advantages of water slurry printing:

(1) Soft touch, the pattern does not affect the softness and breathability of the fabric: Water-slurry printing, with its unique printing method, creates a good combination between the pattern and the fabric while retaining the original texture. This means that even if the fabric is printed with a pattern, its softness and breathability will not be significantly affected. When wearing clothes made of water-slurry printed fabrics, people can feel a comfortable touch similar to that of unprinted fabrics. Many consumers favor this soft touch.

(2) Natural colors, suitable for light-colored fabrics: Water-based printing also has unique advantages in color expression. It can present natural and soft color effects, and it is ideal for printing light-colored fabrics. Compared with some printing methods that may cause colors to be too bright or stiff, the colors of water-based printing are closer to nature, giving people a warm and comfortable feeling. In addition, since light-colored fabrics are lighter in color, water-based printing can better blend into them, making the pattern and fabric complement each other.

(3) Relatively environmentally friendly, using fewer chemicals: Environmental protection has become an increasingly important issue in today's society. As a relatively environmentally friendly printing method, water slurry printing uses fewer chemicals in its production process. This helps reduce pollution and environmental damage while meeting consumers' demand for green and healthy products. Therefore, water slurry printing has become more environmentally friendly and sustainable when choosing a printing method.

As a traditional printing process, water slurry printing has the advantages of environmental protection and bright colors. Still, it has some apparent disadvantages in practical applications, such as fragile covering power and average washability. The reasons are as follows:

(1) Water-based printing has weak covering power and is not suitable for dark fabrics

Characteristics of water-slurry printing dyes: Water-slurry printing mainly uses water-soluble dyes or pigments as dyes, which have relatively weak adhesion and covering power on fabrics. When used on dark fabrics, due to the dark color of the fabric itself, the dyes are difficult to cover the base color completely, affecting the clarity and color saturation of the printed pattern.

Difference in permeability: Different fabrics have different fiber structures and water absorption. Dark fabrics tend to have poor water absorption and smaller fiber gaps, making it difficult for the printing and dyeing agents in water slurry printing to penetrate the fibers, thereby reducing the covering effect fully.

Color contrast: The contrast between dark fabrics and light or bright printed patterns is low. Even if the printed pattern is brightly colored, it will appear dim against the dark fabric, affecting the overall visual effect.

(2) The wash resistance of water-based printing is average, and the pattern may fade after multiple washings

Stability of dyes: The dyes used in water-based printing tend to react with water and detergents during multiple washings, gradually causing the color to fade. This fading phenomenon is particularly noticeable on dark fabrics because the dyes in dark fabrics may also migrate or fall off during washing, further exacerbating the fading of the printed pattern.

Influence of washing method: Improper washing method is also an essential reason for the fading of water-based printing patterns. For example, using overheated water for washing, adding strong acid or alkaline solid detergents, soaking for a long time, or vigorous scrubbing may destroy the bonding force between the printing and dyeing agent and the fabric, causing the pattern to fade.

Fabric characteristics: The fiber structure of some fabrics is relatively loose or highly absorbent, and they quickly absorb a large amount of water and detergent during the washing process, causing the printing and dyeing agents to be diluted or washed away, thereby reducing the washability of the pattern.

The poor hiding power and washing resistance of water-slurry printing are generally due to the combined effect of multiple factors, such as the characteristics of the printing and dyeing agent, the water absorption and fiber structure of the fabric, and the washing method. To overcome these shortcomings, measures such as using better quality printing and dyeing agents in the printing process, optimizing the washing method, or choosing fabrics more suitable for water-slurry printing can be taken to improve the printing effect and service life.

     3. puff print

puff print is a printing process that can create a three-dimensional effect. By adding a foaming agent to the printing paste, the printing paste will expand during the heating process to form a three-dimensional foam pattern. This process is often used on clothing, home textiles, and other products to create patterns with unique visual and tactile effects.

Advantages of puff print:

(1) puff print has a strong three-dimensional effect, and the pattern is exciting and decorative. The most notable feature of puff print is its three-dimensional solid effect. Through a unique foaming process, the printed pattern can present a clear concave and convex effect, as if the pattern "floats" out of the fabric. This three-dimensional effect makes the pattern look more vivid and exciting and dramatically enhances its decorativeness. Whether used on clothing, household items, or other decorations, puff print can add a unique charm and appeal to the product.

(2) puff print can create a unique texture and touch, attracting visual attention: In addition to a three-dimensional solid sense, puff print can create a unique texture and touch. When touching the puff print pattern, people can feel the apparent bumps and softness, which is entirely different from flat printing and more fascinating. At the same time, the unique texture of puff print can also attract people's attention visually, making the product more eye-catching. This unique experience that combines vision and touch is one of the reasons why puff print is so popular among consumers.

As a printing process with special three-dimensional effects, puff print can give textiles a unique visual and tactile experience, but it also has some obvious disadvantages.

1. The wear resistance and washability of puff print could be better, and the pattern is easily damaged by friction or washing.

The three-dimensional patterns formed on fabrics by the foaming printing process are beautiful and have a unique touch, but their wear resistance and washability are relatively weak. This is mainly because the bonding force between the foaming printing layer and the fabric substrate is limited, and the foaming material itself may have a certain degree of brittleness. During daily wear and washing, the foaming pattern is easily affected by external forces such as friction and extrusion, causing the pattern edge to wear, bubble, or fall off. In addition, the foaming material may also be damaged during the washing process due to water absorption expansion, uneven shrinkage, etc., thus affecting the integrity and aesthetics of the printed pattern.

2. puff print has high requirements on printing technology, and the foaming process requires precise control of temperature and pressure

The foaming printing process has high requirements for operating technology and equipment conditions. In particular, controlling temperature and pressure is crucial during the foaming process. The foaming temperature and time must be set precisely to ensure that the foaming agent can fully decompose and release gas so that the printing paste expands to form a three-dimensional pattern. At the same time, the control of pressure also affects the uniformity and stability of the foaming. Suppose the temperature or pressure is not adequately controlled. In that case, it may lead to problems such as insufficient foaming, excessive foaming, or uneven foaming, affecting the printed pattern's quality and effect. In addition, the foaming printing process also needs to pay attention to the formula and stability of the printing paste, as well as the precision and strength of the printing equipment, which increases the difficulty and complexity of process control.

While the puff print process gives textiles a unique aesthetic, it also faces challenges such as relatively poor wear resistance and washability, high process requirements, and complex control. Therefore, in practical applications, it is necessary to select appropriate printing processes and materials according to specific needs and conditions and strengthen process control and quality testing to ensure the quality and stability of printed products.

     4. Flock Screen Printing

Flock Screen Printing is a printing method that uses electric current to "plant" short fibers (flocking) onto fabric. This process can make the printed pattern surface appear velvety and is usually used for high-end clothing or household items. flock Screen Printing has a soft feel and unique visual effects, which can increase the product's added value.

Advantages of flock Screen Printing

1. flock Screen Printing is soft to the touch and has a fluffy texture on the surface, which is suitable for high-end products. flock Screen Printing gives the fabric a smooth and delicate touch by planting short fiber fluff on the fabric's surface. At the same time, the presence of fluff also increases the three-dimensional sense and warmth of the fabric. This unique texture makes flock Screen Printing products suitable for high-end clothing, home accessories, and other occasions.

2. The flock Screen Printing has a three-dimensional visual effect, and the pattern is decorative and layered: The flock Screen Printing process can create rich patterns and color effects. Due to the three-dimensional existence of the flock, the pattern is visually fuller and more vivid. This three-dimensional sense not only enhances the decorativeness of the pattern but also makes the entire design more layered and deep, adding a unique artistic charm to the product.

Disadvantages of flock Screen Printing

1. The flock Screen Printing process is complicated, and the cost is high:

flock Screen Printing is relatively complicated and requires multiple processes, including pattern design, plate making, flocking, color fixing, etc. These processes require sophisticated technology and the use of special equipment and materials, so the cost is relatively high. For large-scale production, high costs may become one of the constraints.

2. The fluff is easily damaged and not washable: Although the fluff on the surface of flocking printed products is beautiful and feels good, it also has the disadvantage of being easily damaged. During daily use and washing, the fluff may fall off or deform due to friction, extrusion, etc., thus affecting the appearance and service life of the product. In addition, some detergents and washing methods may also damage the fluff, so special attention should be paid to the washing and maintenance methods.

     5. Foil Printing

foil Printing is a printing process that transfers metal foil to fabric through heat and pressure and is often used to create high-end clothing or products. This process is not limited to gold; it can also use different colors of metal foil, such as silver and laser, to achieve a shiny effect.

Advantages of foil Printing

(1) The foil Printing pattern has a high gloss and firm texture, which can enhance the grade of the product: Imagine that when you see a piece of clothing with a golden or silver pattern, do you think it is particularly dazzling and high-end? This is the charm of foil Printing. It can form a bright, glossy film on the product's surface, making the pattern look more three-dimensional and textured, as if putting on a gorgeous coat for the product instantly enhances the grade and taste of the product.

(2) foil Printing suits various products such as clothing, shoes, hats, bags, etc.. foil Printing has a wide range of applications and can cover almost all products in our daily lives. foil Printing can add a unique charm, whether it is fashionable clothing, personalized shoes, hats, or exquisite bags. This flexibility makes foil Printing a preferred process for many designers and brand owners.

Disadvantages of foil Printing

(1) The wear resistance of foil Printing is average, and the pattern quickly fades or falls off during use or washing. Although foil Printing looks gorgeous, its wear resistance is relatively average. In daily use, if the product is often rubbed or squeezed, the foil Printing pattern may fade or fall off. Especially during the washing process, if it is not handled correctly, it may also cause damage to the pattern. Therefore, special attention should be paid when using and maintaining foil Printing printed products to avoid excessive friction and washing.

(2) foil Printing requires high temperature and pressure control and is difficult to operate: The foil Printing process may seem simple but requires exact temperature and pressure control. If the temperature or pressure is set correctly, it may lead to satisfactory foil Printing results or even damage the product. Therefore, this process requires the operator's skills and experience. For beginners or those not skilled enough, they may face specific operational difficulties and challenges.

     6. Luminous printing

Luminous printing is a process that makes the pattern glow in the dark by adding luminous materials to the printing paste. This printing method is often used for children's clothing, outdoor clothing, or clothing with a specific theme, which is very interesting and functional.

Advantages of luminous printing

The most attractive feature of luminous printing is its ability to emit light in the dark. This unique visual effect adds interest to the product, allowing people to see beautiful patterns or logos at night, and has certain functionality. For example, luminous printing on children's clothing or toys can make it easier to find children at night, increasing safety; using it on outdoor products can provide directional guidance or decorative effects at night, improving the user experience.

Luminous printing suits specific markets and consumer groups, such as children's clothing, outdoor products, etc. The unique charm of luminous printing makes it ideal for some particular markets and consumer groups. Children are curious about new things, and luminous printing can attract their attention and increase the product's attractiveness. Outdoor enthusiasts value the practicality and uniqueness of the product, and the luminous effect of luminous printing at night meets their needs. Therefore, these markets and consumer groups have become the main target objects of luminous printing products.

Disadvantages of luminous printing

The luminous effect will gradually weaken, and its durability is average. Although luminous printing can emit an attractive glow in the dark, this effect is not permanent. Over time and with frequent use, the luminous material will gradually lose its luminous properties, causing the luminous effect to weaken or even disappear. This means that the service life of luminous printing products is relatively short and requires regular replacement or maintenance to maintain its luminous effect. In addition, the durability of luminous materials is average, and the external environment easily damages them.

The cost of luminous printing is relatively high, and the market demand is limited. The luminous printing process is relatively complicated and requires unique materials and printing technology, so its production cost is relatively high. This leads to the relatively high selling price of luminous printing products, which may be beyond the budget of some consumers. At the same time, due to the particularity and limitations of luminous printing, its market demand is also relatively limited. Although it is popular in some specific markets and consumer groups, it may not be competitive enough in the broader market.

     7. Reflective printing

Reflective printing is done by mixing reflective material with printing paste so that the pattern can reflect light under the light. This process is mainly used in safety clothing, sportswear, and other clothing that need to improve visibility and have certain safety functions.

Advantages of reflective printing

The reflective effect is evident, as it improves nighttime safety and is suitable for outdoor sportswear, work clothes, etc.: The biggest highlight of reflective printing is its significant reflective effect. When light shines on the reflective printing at night or in a dimly lit environment, it will immediately reflect a bright light. This effect can significantly improve the wearer's visibility, thereby increasing the safety of nighttime activities. Therefore, reflective printing is very suitable for outdoor sportswear, work clothes, and other clothing that need to improve nighttime safety, providing additional protection for the wearer.

Reflective prints have unique patterns and are highly functional. In addition to the reflective effect, reflective prints attract people's attention with their distinctive pattern design. These patterns often have bright colors and lines, which are beautiful and highly functional. For example, the reflective prints used on traffic warning clothing can convey the identity and intentions of the wearer and increase the alertness of traffic participants; reflective prints used on outdoor adventure equipment can help team members identify each other at night and enhance team collaboration efficiency.

Disadvantages of reflective printing

Reflective prints feel hard, affecting wearing comfort: Although reflective prints are excellent in functionality and aesthetics, their material characteristics may have a particular impact on wearing comfort. Since reflective materials usually have a certain hardness and thickness, reflective prints printed on clothing may make the overall feel of the clothing stiffer. This change in thinking may make some consumers who pursue a soft and comfortable wearing experience feel uncomfortable, especially when wearing clothing that is worn next to the skin.

The reflective effect of reflective printing will weaken over time: The reflective effect of reflective printing is not permanent. As time goes by and the frequency of use increases, reflective materials may be affected by wear and aging and gradually lose their reflective properties. This means that the reflective effect of reflective printing products may weaken progressively or even disappear over time. Therefore, when using reflective printing products, you must pay attention to care and maintenance to extend their service life and maintain their reflective effect.

     8. Silicone printing

Silicone printing is a printing process that has become increasingly popular in recent years. It mainly forms patterns by transferring silicone materials onto fabrics. The pattern surface of silicone printing has a certain degree of elasticity, gloss, and good wear resistance and is widely used in sportswear and footwear products.

Advantages of silicone printing

Wear-resistant, high-temperature resistant, and the pattern is not easily damaged: A significant advantage of silicone printing is its wear and high-temperature resistance. This means that even if rubbed or exposed to high temperatures daily, the silicone printing pattern can remain intact and is not prone to wear or shedding. This is especially important for clothing or products that must withstand a certain amount of wear or high-temperature environments, such as sportswear, outdoor products, etc.

Good elasticity, suitable for application on highly elastic fabrics: Silicone printing also has good elasticity and can maintain the integrity and beauty of the pattern as the fabric expands and contracts. This feature makes silicone printing very suitable for application on highly elastic fabrics, such as stretch sports pants, tights, etc. Silicone printing on these fabrics can closely fit the body curves, showing better wearing and visual effects.

The surface is glossy and has a unique texture. Silicone printing also has an exceptional gloss and texture. Under light irradiation, the silicone printing pattern will present a soft and layered gloss effect, making the entire product look more upscale and refined. At the same time, the texture of silicone printing is also very unique, with a certain degree of hardness and a certain degree of softness, giving people a feeling of both stiffness and comfort.

Disadvantages of Silicone Printing

Silicone printing is more expensive, and the production process is more complicated. Compared with other printing methods, the cost of silicone printing is usually higher. This is mainly because the production process of silicone printing is relatively complex, requiring unique materials and multiple processes to complete. Therefore, the price of silicone printing products is also relatively high, which may exceed the budget of some consumers.

Compared with water slurry printing, the surface of silicone printing is more complex and less soft than water slurry printing: Although silicone printing has a unique gloss and texture, its pattern surface is relatively complex. This hardness may affect the comfort of wearing, especially on clothes next to the skin. In contrast, printing methods with better softness, such as water slurry printing, may feel more comfortable. Therefore, when choosing a printing method, it is necessary to make comprehensive considerations based on specific needs and product characteristics.

   9. Discharge printing

Discharge printing is a process that removes the original dye on the fabric through a chemical reaction to form a pattern. This process is mainly used for dark fabrics. After the dye is removed by a decolorizer, a white or light pattern can be formed on the fabric.

Advantages of discharge printing

The pattern of discharge printing is integrated with the fabric and feels great. One of the significant advantages of discharge printing is that its pattern can be perfectly integrated with the fabric, and it is almost impossible to see the traces of printing. This is because discharge printing removes part of the color on the fabric through chemical treatment, thereby revealing the pattern. This treatment method makes the pattern and the fabric almost the same in texture and touch, giving people the feeling that the pattern grows naturally from the fabric. Therefore, clothing or products with discharge printing usually have an excellent feel and are comfortable to wear.

Discharge printing is particularly suitable for printing on dark fabrics with clear and natural patterns. Traditional printing methods often fail to achieve the desired effect because the color of the dark fabric itself will cover up the color of the printed pattern. Discharge printing is different; it can create clear and natural patterns that affect dark fabrics. This is because discharge printing forms patterns by removing part of the color on the fabric, so even dark fabrics can present a vivid pattern effect. This makes discharge printing an ideal choice for printing on dark fabrics.

Disadvantages of discharge printing

Chemical treatment has some damage to the fabric and poor durability: Although discharge printing can create unique pattern effects, its chemical treatment process may cause some damage to the fabric. This is because discharge printing requires chemicals such as strong acids or strong alkalis to remove the color of the fabric. These chemicals may damage the fiber structure of the fabric, resulting in reduced durability of the fabric. Therefore, when using discharge printing products, you must pay attention to care and maintenance to extend their service life.

Discharge printing has high technical requirements and requires precise chemical reaction time and concentration control. The production process of discharge printing is relatively complex and highly demanding. During the production process, the time and concentration of the chemical reaction need to be precisely controlled to ensure the clarity and naturalness of the pattern. If the chemical reaction time or concentration is not adequately controlled, it may lead to problems such as blurred patterns and uneven colors. Therefore, discharge printing requires a high level of technical skills and experience from the technician. This also makes the production cost of discharge printing products relatively high and the production cycle long.

     Screen printing process selection guide

Faced with various screen printing processes, choosing the proper process depends on many factors, including material, purpose, pattern design, and budget. You can consider the following aspects:

1. Material requirements: If it is used for cotton or other natural fiber fabrics, Rubber Printing and water slurry printing are good choices; if it is synthetic fiber or unique materials, such as nylon, polyester, etc., silicone printing and foil Printing printing are more suitable.

  

2. Pattern design: For complex patterns or designs that need to highlight the three-dimensional effect, you can choose puff print or flock Screen Printing; for designs that pursue gloss and fashion, you can consider foil Printing printing or reflective printing.

3. Purpose and function: For functional needs such as safety clothing and outdoor sportswear, reflective printing or luminous printing can be selected; for high-end products, flocking or silicone printing can be chosen to enhance the product texture.

As a flexible and diverse printing process, screen printing maintains its essential position in various industries with its rich process types and wide application range. Whether it is traditional Rubber Printing, water slurry printing, or more modern silicone printing, luminous printing, etc., each process has unique advantages and applicable scenarios. In practical applications, only by choosing the most appropriate method according to the product's specific needs can the printing effect and product value be maximized.