Screen printing is the historical gold standard of mass apparel decoration. Photographic emulsion is exposed to UV light to create a stencil on polyester mesh screens (typically 110 to 230 threads per inch). In automated carousel presses, rubber squeegees force viscous plastisol or water-based inks through the open mesh pores onto the t-shirt. The garment travels through a forced-hot-air conveyor dryer at 160°C to cure the ink, yielding unmatched durability and bulk unit cost efficiency for runs of 50 to 50,000+ pieces.
The Industrial Mechanics of Automated Screen Printing
Commercial screen printing utilizes circular automatic rotary carousel presses capable of printing 500 to 900 garments per hour. Each color in the graphic requires its own independent screen mesh, aluminum frame, and photographic exposure process.
A rubber squeegee angled at 75 degrees shears the ink across the stencil under pneumatic pressure, depositing a calibrated layer of ink onto the garment. Flash cure units flash the ink surface dry for 3 seconds between stations, allowing subsequent colors to be layered cleanly without smearing.
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