Most screen printing comes down to three kinds of ink: plastisol, water-based and discharge. Each one prints, cures and feels different, and each suits different garments. Here's what separates them and how to choose.
Plastisol
Plastisol is PVC particles suspended in a plasticizer. It doesn't air-dry, so it stays workable in the screen for as long as you need, which makes it forgiving for long runs and new printers. It cures with heat, typically around 320°F through the full ink film; check your ink maker's spec sheet for the exact temperature and time. It sits on top of the fabric, gives bright, opaque color on dark garments over an underbase, and has a slightly raised, smooth feel.
Water-based
Water-based ink soaks into the fabric instead of sitting on it, so the print feels soft, close to the shirt itself. It's at its best on light, cotton-heavy garments. It can dry in the screen, so it needs to keep moving and the screens kept flooded, and it's only cured once the water has fully evaporated, which usually means longer in the dryer than plastisol.
Discharge
Discharge ink uses an activator to remove the garment's dye where it prints, and can add color at the same time. The result is a very soft print on dark garments with no heavy underbase. It only works on garments dyed with dischargeable (reactive) dyes, which mostly means 100% cotton, so test the exact style and color first. It also needs good ventilation while it cures.
Which one to use
- Bright, opaque color on darks, any fabric blend: plastisol over an underbase.
- Soft hand on light cotton: water-based.
- Soft hand on dark 100% cotton: discharge, after a test print.
- Specialty finishes like puff, metallic and glitter are mostly plastisol additives or specialty plastisols.
What ink costs per print
Ink is a small part of most job costs, but it's worth knowing. A gallon is 231 cubic inches, and one print puts down the design area times the ink thickness, plus whatever is wasted in screens and buckets. Our free ink cost calculator does the math from your gallon price, design size and deposit.
Common questions
- What is the most common screen printing ink?
- Plastisol. It stays workable in the screen, prints bright on dark garments and works on most fabric blends.
- What temperature does plastisol cure at?
- Typically around 320°F through the whole ink film, but it varies by ink. Use the temperature and time on your ink's spec sheet.
- Can discharge ink be used on polyester?
- Generally no. Discharge removes reactive dyes, which are used on cotton. Test the exact garment before you take an order.