Multi-Color Designs With Screen printing is an art form. We'll be the first ones to tell you that. Even when the process evolves, it's as if each design has a soul...
November 30, 2023
In the screen printing industry, there is a lot of focus on the material a design is printed on. Of course that makes sense, it's the foundation for everything else. Think of it as a garden. The base is the soil, the better the soil, the better the garden. That's why you hear a lot of talk about brands like Allmade and Original Favorites. Top-notch soil so to speak. But I can bet you never walked by a beautiful flower garden and said, "Man...take a look at that soil, it's epic!".
It's the same with your merch line. A great quality base sets the stage for a great design, but multi-color designs are the "flowers" in the garden of screen printing. So, the question remains...how do you get a vibrant multicolor design out of your imagination, or even graphic design software and onto a garment?
In this blog, we are digging up the top ways we achieve multi-color designs at our shop, Superior Ink Screen Printing Denver, CO.
If you are ready to merge multiple colors with a freaking awesome design to make merch your people will dig keep reading! (Our apologies...we had to pull that garden reference through somehow 😉).
Spot color printing's uniqueness lies in its method of using specially formulated inks for each color in a design, a feature that sets it apart from other printing methods. This allows for unparalleled color accuracy and consistency, crucial for branding and corporate identity, where specific colors are often trademarked or integral to brand recognition. Unlike CMYK or other process printing methods that approximate colors by blending basic inks (more on that further down...patience young padawan), spot color printing uses inks that are precisely mixed to the desired hue before application.
Another aspect that makes spot color printing stand out is its scalability in terms of cost. While it's more economical for simple designs with few colors, the cost can increase with the addition of more colors, as each requires its own screen. However, for large-scale print runs, this method remains cost-effective due to the long-lasting quality and consistency of the prints. In addition, the vibrancy and saturation achievable with spot color printing are often superior to other methods.
Pro Printer Tip: Hot market printing with fast turnaround times and completely accurate color demands thrive on spot color printing. Perfect accuracy everytime makes this an effective printing method for big projects that may include a logo registration mark.
Spot color printing also offers a quicker setup and printing process for designs with fewer colors, contributing to faster turnaround times for projects. This efficiency, combined with its color precision and consistency, makes it an ideal choice for businesses and organizations that require high-quality prints in large quantities, such as for merchandise, uniforms, or promotional materials (a.k.a. perfect for building your brand recognition!).
The four-color process printing technique, grounded in the CMYK color model, utilizes the primary colors Cyan, Magenta, Yellow, and Key (Black) to produce a wide range of hues. In this method, a color image is meticulously separated into these four distinct color values. This separation is accomplished using specialized filters and screens, each designated to isolate one of the CMYK colors from the original image.
The process involves breaking down a complex, multi-colored design into four simpler components. Each component corresponds to a single CMYK color and is printed using its own screen. The printer layers these four colors, one atop the other, to reconstruct the full spectrum of colors present in the original image. It's printed wet on wet unless you are using a white under base, in that case, the under base is cured to give a foundation on top of a dark garment. It's akin to an artist mixing primary colors on a palette to create a multitude of shades and tones.
Pro Printer Tip: Choosing the correct squeegee is crucial for optimal results in four-color process printing. Ensure its tension is precisely adjusted and that it can swiftly snap away from the ink. This helps avoid any blurring and maintains the sharpness of your vibrant design.
This method is particularly efficient and cost-effective for producing high-quality, detailed designs. With just four screens—one for each CMYK color—printers can achieve intricate patterns and a broad array of colors. This makes four-color process printing a popular choice for high-volume orders since the screens take quite a bit to set, but are super efficient after they are ready.
The end result of this process is a composite image that seamlessly blends the four base colors to display the full-color range of the original design. This blending creates an illusion of a much larger color palette, allowing for the reproduction of intricate, multi-colored designs with a relatively simple and economical printing setup.
Plastisol ink, a mainstay in the screen printing industry, can be likened to a shape-shifter due to its unique properties. Initially, it exists as a semi-liquid blend, composed of synthetic resin particles suspended in a stable liquid. This formulation allows it to rest on top of the fabric's surface, rather than penetrating the fibers like other inks. This surface-level application is key to its popularity among screen printers, as it provides ease of use and adaptability across a wide range of fabric types. However, this method results in prints that are noticeably thicker, giving the fabric a distinctive texture.
The screen printing process with plastisol begins with careful preparation. A stencil or screen featuring the desired design is crafted, and the fabric is positioned on the printing press. The plastisol ink is then evenly applied over the screen using a squeegee. The transformative moment occurs when the ink is subjected to heat, usually around 320°F (160°C) in a conveyor dryer. This heat exposure shifts the ink from its relaxed liquid state to a durable, solid print on the fabric.
Pro Printer Tip: Plastisol can be super versatile, but a good screen printer, or any producer of garments on a large scale takes into account the implications of using an unsustainable and biodegradable plastic product on both the earth, and the consumers future.
While plastisol offers numerous benefits in screen printing, it's important to consider its environmental impact. The ink's reliance on PVC (polyvinyl chloride) poses environmental concerns. PVC is not easily biodegradable, and its production process releases harmful chemicals, presenting challenges for sustainability. Despite these issues, plastisol remains a historically popular choice in screen printing due to its user-friendliness and versatility with various fabrics, although the thickness of the resulting prints is a notable drawback.
At its core, this simulated process printing employs halftone dots, a printing technique where tiny dots of different sizes and spacings are used to create the illusion of various shades and multiple colors. These halftone dots, representing a limited palette of spot colors, are carefully overlaid on top of each other. As they intersect and overlap, they give the impression of a vast array of colors, mimicking the effect of mixing primary colors to achieve secondary hues.
However, unlike traditional color mixing, this process does not blend the inks themselves. Instead, it relies on the optical illusion created by the placement and interaction of the halftone dots. This sophisticated technique allows for the simulation of a full-color image with a much smaller set of ink colors, making it a cost-effective option for complex designs.
Pro Printer Tip: On dark fabrics, apply a white under base initially. This underbase primes the surface, ensuring that the overlaying colors in the simulated process remain vivid and true to the original design.
Simulated process printing is particularly effective for raster-based artwork, which includes digital images made up of tiny pixels. This method can accurately replicate the subtle gradations and color variations found in detailed photographs or intricate digital art. By using only a select few ink colors, this technique can reproduce designs that appear to have a wide spectrum of colors.
Discharge ink is a specialized type of water-based ink used in the screen printing process. It contains an activator, often referred to as a discharging agent, which serves a crucial role in transforming the color of the fabric. When discharge ink is applied to a shirt, the discharging agent interacts with the dye in the fabric, essentially bleaching it back to its natural bone color. This initial step is essential as it prepares the fabric for the desired pigment color.
Pro Printer Tip: While experienced printers can work with slightly darker fabrics, light-colored fabrics are recommended for optimal outcomes. Choosing the right fabric color is crucial to ensure the vibrancy and accuracy of the final print, as well as the soft feel associated with water-based discharge printing.
Once the fabric is returned to its base color, pigments can be added to the discharge ink to create the desired hue. This process allows for vibrant and opaque colors to be printed on the fabric while maintaining a soft and smooth texture. Unlike traditional plastisol inks, which can result in a heavy, rubbery feel on the garment, discharge ink, when applied correctly, provides a much softer hand (feel). After the garment is printed and heat-cured, you should not be able to feel the ink on the fabric once it's been properly washed and cured.
The hybrid printing process often begins with discharge dyeing. This involves using a discharge ink that, when applied to the fabric, removes or discharges the existing color from the fabric. This step is particularly effective on dark-colored fabrics. After discharge dyeing, a base screen is used. The base screen typically involves a water-based ink that integrates with the fabric. This integration creates a foundation for the subsequent layers of ink to adhere to. On top of the integrated base color, soft hand plastisol ink is applied. The "soft hand" refers to the ink's texture and feel, which is smooth and comfortable on the fabric.
Hybrid printing combines the advantages of both discharge dyeing and plastisol inks. As a result, it delivers vibrant and long-lasting colors that pop on the fabric. One of the primary benefits of this process is the creation of a soft print. Unlike some traditional plastisol prints that can feel heavy or stiff on the fabric, hybrid printing produces a print with a comfortable, soft texture. The base color, achieved through discharge dyeing, integrates into the fabric itself. This integration not only enhances the color vibrancy but also ensures that the print becomes a part of the fabric rather than sitting on top of it.
To us, screen printing truly is the art we showcase to the world. Just like an artist selecting the right paintbrush, the way a screen printer creates a multi-color design is part of the process.
Each method we've explored at Superior Ink Screen Printing in Denver, CO, offers its own set of advantages, suited to different design needs, fabric types, and color requirements. Whether it’s the precision and scalability of spot color, the intricate detail achievable with the four-color process, the durability and boldness of plastisol, the realistic and artistic capabilities of simulated process printing, or the vintage charm and soft feel of discharge water-based printing, there's a perfect method for every vision.
We of course like to bring our own flair with hybrid printing, blending the best of discharge dyeing with soft hand plastisol, which opens up new realms of creativity.
As screen printers and artists, we are committed to pushing the boundaries of what's possible, crafting merchandise that not only looks spectacular but also tells a story and embodies the soul of the design while honoring the planet that supports us.
