Screen Printing (Silk Screen)
The industry standard for bold, opaque prints at scale
Screen printing is the most cost-effective method for large orders (100+ units) with limited colors (1-6). It produces the most opaque, vibrant, and durable prints available — the industry standard for promotional apparel.
- Most cost-effective for 100+ units (per-unit cost drops dramatically)
- Maximum opacity and vibrancy — thickest ink deposit
- Each color = separate screen ($25-35 setup per color)
- Best for: simple logos, text, solid shapes with 1-6 colors
- Specialty inks: metallic, glow-in-dark, puff, discharge
What is Screen Printing (Silk Screen)?
Screen printing pushes ink through a mesh stencil (screen) onto the garment surface. Each color requires a separate screen. It produces the most opaque, vibrant prints with excellent durability — and is the most cost-effective method for large-batch orders.
Technical Specifications
- Colors per Design
- 1-8 (each = separate screen)
- Ink Type
- Plastisol (standard), water-based, discharge
- Opacity
- Highest of all methods
- Max Print Area
- 14" x 17" (35 x 43 cm)
- Screen Mesh
- 110-305 mesh (varies by detail)
- Durability
- 100+ washes
- Setup
- $25-35 per color per screen
- Sweet Spot
- 100-10,000+ units
File Requirements
- File Format
- Vector (AI, EPS, SVG) strongly preferred
- Resolution
- 300 DPI minimum for raster
- Colors
- Must be separated — max 8 spot colors
- Color Specification
- Pantone (PMS) colors required for matching
- Halftones
- Possible but limited (simulated process)
Best For
- Bulk promotional apparel (100+ units)
- Simple logos and text designs
- Event merchandise and giveaways
- Team uniforms (solid logos)
- Designs requiring maximum opacity
- Specialty effects (metallic, glow, puff)
Not Ideal For
- Photographic or gradient images
- Designs with 8+ colors (use DTG)
- Single-unit or very small orders
- Frequently changing designs
Advantages
- Lowest per-unit cost for large orders
- Most opaque and vibrant prints
- Extremely durable (100+ washes)
- Specialty inks available
- Industry standard — proven quality
Limitations
- Per-color screen setup cost
- Not cost-effective under 50 units
- Limited to 8 spot colors
- Cannot reproduce photographic detail
- Setup time (screen creation)
Compatible Products
Production Details
- Lead Time
- 5-10 business days (includes screen setup)
- Minimum Order
- 25 units recommended (1 unit technically possible)
- Maximum Print Area
- 14" x 17"
- Cost Range
- $3-8 per unit at 100+ quantity
Care Instructions
- Machine wash inside-out
- Tumble dry on low
- Extremely durable — minimal care needed
Screen Print FAQ
What is the minimum order for screen printing?
While technically possible to screen print 1 unit, the per-color screen setup cost ($25-35/screen) makes it uneconomical for small orders. We recommend 25+ units minimum for screen printing to be cost-effective. For 1-24 units, DTG or DTF is more practical.
How much does screen printing cost?
Screen printing cost depends on quantity and colors. A 1-color print on 100 t-shirts typically costs $3-5/unit. A 4-color print on 500 units costs $4-7/unit. Setup fees ($25-35/color) are one-time charges.
Can screen printing do gradients?
Standard screen printing uses spot colors, not gradients. However, "simulated process" screen printing uses halftone dots to approximate gradients with 4-8 screens. For true photographic gradients, DTG or DTF is recommended.
What are specialty screen print inks?
Available specialty inks include: metallic/foil (gold, silver), glow-in-the-dark, puff (3D raised texture), discharge (removes dye for soft hand feel on dark garments), and high-density (extra-thick raised print).
How long do screen prints last?
Screen prints are the most durable decoration method alongside embroidery — lasting 100+ washes. Plastisol inks create a thick, flexible layer that resists cracking and fading far better than digital printing methods.
Screen print vs DTG: when to choose which?
Choose screen print for: 50+ units, simple designs (1-6 colors), maximum opacity, and lowest per-unit cost. Choose DTG for: 1-49 units, complex multicolor/photographic designs, and quick turnaround without setup fees.
Other Print Techniques
Ready to Start Screen Print Printing?
Choose a product, review its template, and prepare artwork for the selected production method.
