Screen printing is a versatile and popular printing method used to create custom designs on various surfaces, including clothing, posters, and promotional materials. One critical aspect of screen printing that directly impacts the quality and accuracy of the printed design is the mesh count of the screen. The mesh count refers to the number of threads per inch in the screen, and it plays a significant role in the clarity and precision of the print.
Despite its importance, many beginners and even experienced printers make mistakes when choosing or using mesh counts. These mistakes can lead to poor-quality prints, wasted materials, and increased production costs. In this article, we'll explore the common mesh count mistakes in screen printing and provide practical tips on how to avoid them.
What Is Mesh Count in Screen Printing?
Before diving into the mistakes, it's essential to understand what mesh count is and how it affects your printing process. Mesh count refers to the number of threads per inch in the screen mesh. The higher the mesh count, the finer the threads, which allows for more intricate details in the print. Conversely, a lower mesh count means the threads are thicker and better suited for printing thicker inks or designs that require more coverage.
Mesh count is often chosen based on the type of ink, the complexity of the design, and the type of fabric or material being printed on. The most common mesh counts used in screen printing range from 110 to 305 threads per inch, with higher numbers being used for fine details and lower numbers for heavier inks or thicker designs.
Common Mesh Count Mistakes and How to Avoid Them
1. Using the Wrong Mesh Count for the Ink Type
One of the most common mistakes in screen printing is using the wrong mesh count for the type of ink you're working with. Different inks have different viscosities and particle sizes, which require different mesh counts to achieve the best results.
How This Mistake Happens:
- Using a fine mesh count (e.g., 230 or 305) with heavy inks like plastisol can cause the ink to clog the screen or not pass through evenly, leading to uneven prints or incomplete designs.
- On the other hand, using a low mesh count (e.g., 110 or 156) with very thin inks like water‑based ink can result in too much ink being deposited on the material, leading to a messy or over‑saturated print.
How to Avoid It:
- For thicker inks like plastisol or high‑opacity inks, use a lower mesh count (110 to 156) to ensure proper ink flow without clogging the screen.
- For thinner inks like water‑based or discharge inks, use a higher mesh count (200 to 305) to ensure finer detail and better ink control.
- Always check the manufacturer's recommendations for ink and mesh compatibility for the best results.
2. Choosing a Mesh Count Based on the Design Complexity Alone
Another common mistake is choosing a mesh count based solely on the design complexity or the level of detail. While the design's intricacy plays a role, it's essential to consider the other factors, such as ink type and fabric, before deciding on the mesh count.
How This Mistake Happens:
- Many printers assume that the more intricate the design, the higher the mesh count should be. While this is true for designs with very fine details, it doesn't account for other factors such as ink opacity and fabric type, which also influence the print quality.
- For example, if you choose a mesh count that's too high for a design with heavy ink or a thick fabric, you may end up with a print that lacks vibrancy or is inconsistent in coverage.
How to Avoid It:
- Balance design complexity with ink and fabric choice. For fine details and light inks, a higher mesh count is ideal. However, for heavier designs or darker inks, opt for a lower mesh count to ensure proper ink flow and even coverage.
- Test your screens and prints with different mesh counts to find the optimal combination for each project, considering the design complexity and material.
3. Not Accounting for Ink Build‑Up on High Mesh Counts
When using higher mesh counts (e.g., 230 or 305), one common issue is that ink can build up in the finer threads, especially when printing large or solid areas. This can lead to over‑saturation, where the ink becomes too thick or unevenly distributed across the design.
How This Mistake Happens:
- Fine threads in high mesh count screens can trap ink and cause the ink layer to become too thick or uneven, especially when printing large or solid areas.
- Printers often focus on the design and forget to account for how the ink will behave on high mesh counts, leading to a compromised final print.
How to Avoid It:
- For solid areas or large sections of color, consider using a lower mesh count to allow for better ink flow.
- When using a higher mesh count for detailed designs, use lower viscosity inks that flow more easily through the mesh.
- Test your setup before proceeding with a full print run, especially when printing solid areas.
4. Using the Same Mesh Count for All Prints
It's tempting to use the same mesh count for all your screen printing projects, especially if you're just starting out. However, this can lead to suboptimal results, as different designs, inks, and fabrics require different mesh counts.
How This Mistake Happens:
- Many printers default to a specific mesh count (e.g., 156) for all projects without considering the specific needs of the ink, fabric, or design. This lack of flexibility can result in prints that are either too thick, too thin, or lacking in detail.
How to Avoid It:
- Use different mesh counts for different needs. For example:
- Invest in a variety of screens to cover a range of mesh counts, allowing you to adapt to different printing needs.
5. Neglecting Mesh Tension and Quality
Mesh count is only one part of the equation. The tension of the screen mesh also plays a crucial role in achieving a successful print. A mesh that is too loose or too tight can result in inconsistent prints, no matter what the mesh count is.
How This Mistake Happens:
- Many printers focus solely on the mesh count and overlook the importance of mesh tension. A loose or poorly stretched mesh can cause ink to bleed, leading to blurry prints, while a too‑tight mesh can result in inconsistent ink flow.
How to Avoid It:
- Ensure proper mesh tension. Always check that your mesh is properly stretched and taut. Aim for a tension level that is suitable for the type of print you're making. For tools and accessories that help with this, see mesh tension.
- Consider using mesh with higher‑quality fabric that maintains its tension over time and provides better ink control. If you need to purchase new screens, searching for screen printing mesh will give you many options.
Conclusion
Mesh count is one of the most important decisions in screen printing, and understanding how to choose the right mesh for each project is crucial for achieving high‑quality prints. By avoiding common mistakes such as using the wrong mesh count for the ink, not considering design complexity, and neglecting mesh tension, you can ensure that your screen printing process is efficient and produces the best possible results.
As a screen printer, it's essential to experiment and adjust your techniques based on your specific needs. By paying attention to these details and continually learning, you'll be well on your way to mastering the art of screen printing.