Printing Planet UK
Screen printing is the oldest and most established method of printing designs onto fabric. It is the default method for large uniform orders, branded merchandise and band T-shirts, and for good reason. At scale, no other method produces as consistent a result at as low a unit cost.
How It Works
Each colour in a design requires a separate stencil (called a screen). The screen is a fine mesh stretched over a frame. The stencil blocks ink from passing through the mesh except where the design element appears.
The screen is positioned over the garment. A thick, opaque ink (called plastisol) is poured at one end of the screen. A squeegee is drawn across the screen under pressure, pushing the ink through the open areas of the mesh and onto the fabric below.
After printing, the ink is passed under a heat curer (usually a conveyor dryer at around 160 degrees Celsius). The heat fuses the plastisol permanently into the fabric fibres.
A five-colour design requires five screens, five ink mixing steps, five pass-throughs on the press and five separate cure runs.
Pros
- Vivid, opaque colour. Plastisol ink sits on top of the fabric with high opacity. White on black is sharp and solid.
- Durable. Correctly cured screen print ink lasts 100 plus wash cycles.
- Low unit cost at volume. Once screens are made, printing speed is fast. At 100 plus units the unit price drops below most other methods.
- Consistent. Every unit in the run looks identical. Digital methods have minor colour variation.
Cons
- Setup cost per colour. Each screen costs money to produce. A one-colour job at 10 units may cost less than 5 units with a five-colour job.
- Minimum order quantity. Setup cost per colour makes very small orders uneconomical.
- No photographic gradients. Fine gradients and photographs do not reproduce well through a mesh. Halftone dots can simulate gradient effects, but it is a skilled process.
- Colour change cost. Each colour requires a separate ink mix. Pantone matching for brand colours adds cost.
Comparison Table
| Factor | Screen Print | DTG | DTF | Vinyl |
|---|---|---|---|---|
| Best fabric | Cotton | 100% cotton | Most fabrics | Most fabrics |
| Colour vibrancy | Excellent | Good | Very good | Good |
| Gradients/photos | Limited | Excellent | Very good | No |
| Durability | 100+ washes | 30 to 50 | 50+ | 30 to 50 |
| Setup cost | Per colour | None | None | None |
| Minimum order | 12 to 25 | 1 | 1 | 1 |
| Unit cost at 100+ | Lowest | Medium | Medium | Medium |
Typical Minimum Orders and Pricing
| Colours | MOQ | Approx Price Per Unit at 50 |
|---|---|---|
| 1 | 12 | From £7 |
| 2 | 24 | From £9 |
| 3 | 24 | From £11 |
| 4+ | 50 | From £14 |
Setup charges apply per colour per job. Exact pricing depends on garment type, ink type and placement.
For garment printing quotes, visit the garment printing service page.