Plastisol ink is one of the most popular choices for screen printing due to its versatility, durability, and ease of use. It is a go-to ink for many screen printers who want vibrant, long-lasting prints. Whether you’re new to plastisol screen printing or looking to refine your skills, this guide will cover everything you need to know about working with this type of ink.
What is Plastisol Ink?
Plastisol ink is a PVC-based ink used primarily in screen printing. It consists of two main components: a plasticizer and a resin. Unlike other inks, it does not air-dry; instead, it requires heat to cure and bond to the fabric. Once cured, the ink forms a durable layer that can withstand repeated washes, making it ideal for creating high-quality prints on textiles.
Why Choose Plastisol Ink for Screen Printing?
There are several reasons why plastisol ink screen printing is so popular:
- Vibrant Colors: Plastisol ink is known for producing bright, opaque colors on both light and dark fabrics. Unlike water-based inks, which may appear dull on darker textiles, plastisol prints remain vivid.
- Durability: One of the key advantages of plastisol printing is its durability. When properly cured, the ink forms a solid, rubber-like layer that resists fading, cracking, and peeling over time.
- Ease of Use: Plastisol ink printers find it easier to work with this ink because it doesn’t dry in the screen during long printing runs. This allows for more flexibility during production without worrying about clogging the screens.
- Versatility: Plastisol screen printing works well on a wide variety of fabrics, from cotton to polyester. This flexibility makes it a great choice for printing on t-shirts, hoodies, and other apparel.
How to Print with Plastisol Ink
The process of plastisol screen printing involves several steps that are crucial for achieving a high-quality print. Here’s a breakdown of the basic process:
1. Preparing the Screen
Before you start printing, you need to prepare the screen. This involves applying a photo-sensitive emulsion to the mesh and then exposing it to light with your desired design. The areas that were blocked by the design will remain soft, allowing the plastisol ink to pass through during printing.
2. Printing the Design
Once the screen is ready, place your garment on the printing press. Use a squeegee to push the plastisol ink through the screen onto the fabric. The ink will sit on top of the fabric rather than soaking into it, which creates the distinctive look and feel of a plastisol screen print.
3. Curing the Ink
Curing is one of the most important steps in plastisol ink screen printing. To properly cure the ink, you need to expose it to temperatures of around 320°F (160°C). This heat causes the plasticizer and resin in the ink to bond, creating a durable print. If the ink is not properly cured, the design can crack or peel after washing.
4. Testing and Quality Control
After curing, it’s essential to perform a stretch test on the garment to ensure the ink has properly adhered. A good plastisol print should stretch with the fabric without cracking. If the print cracks, it likely means the ink was under-cured.
Common Mistakes to Avoid with Plastisol Ink
While plastisol printing is relatively easy, there are some common mistakes that beginners should watch out for:
- Under-curing the Ink: If the ink isn’t cured at the right temperature or for the correct amount of time, it can peel or crack after a few washes. Always check your curing equipment and test the ink’s adhesion.
- Overloading the Screen with Ink: Using too much ink can result in a thick, heavy print that may not cure properly. Stick to the recommended ink thickness for best results.
- Not Using the Right Mesh Size: Different mesh sizes will affect how much ink is deposited on the fabric. A finer mesh is best for detailed designs, while a coarser mesh is better for heavy ink deposits.
Tips for Getting the Best Results with Plastisol Ink
Here are some tips to ensure your plastisol ink screen printing projects are successful:
- Use a Flash Dryer: A flash dryer can help you partially cure the ink between colors when doing multi-color prints. This ensures that the ink layers do not blend together and keeps each color distinct.
- Keep Your Screens Clean: While plastisol ink doesn’t dry on the screen as quickly as water-based inks, it’s still important to clean your screens after each run. Residual ink can clog the mesh and affect future prints.
- Adjust for Different Fabrics: While plastisol ink works on a variety of fabrics, you may need to adjust your printing technique for different materials. For example, printing on polyester may require the use of a low-bleed ink to prevent dye migration.
Environmental Considerations
One of the downsides of plastisol ink is that it’s not as eco-friendly as water-based inks. Because it contains PVC and requires chemicals for clean-up, it’s essential to take proper precautions when disposing of leftover ink and chemicals. Some manufacturers are working on more environmentally friendly versions of plastisol ink, so it’s worth exploring those options if sustainability is a priority.
Conclusion
Plastisol screen printing is a versatile, durable, and vibrant method for creating high-quality prints on garments. Its ease of use and ability to work on a wide range of fabrics make it a favorite among many screen printers. By understanding how to properly use and cure plastisol ink, you can produce professional-looking prints that stand the test of time. Whether you’re a beginner or an experienced plastisol ink printer, following the right techniques will help you get the best results with every print.