How to make a screen:

Not many people understand the prep work that goes into printing up a tshirt. Having someone email you asking to make ONE shirt can obviously be done but you have to understand the time and cost that goes into setting up the job.

#1: Start with your blank screen with the correct mesh for the job you are printing. 110 is the basic mesh count used for most jobs unless you are dealing with really thin lines or half tones. You need to coat your screens in a darkroom or quickly set them in a light safe area until they are dry.

#2: Pour your emulsion into the coater and apply. You tilt the screen at an angle and evenly coat the screen on both sides.

#3: Emulsion is a light sensitive liquid that needs to dry on the screen in complete darkness or in a darkroom. If you dont have access to a darkroom you can find any light safe area to place your screens. If you have the correct amount of airflow or fans going they should be ready to go in about a half hour. If you are using a closet or other constricted area it could take a while. Making a drying rack that is light tight can be done with some wood and dark black fabric.

#4: Each color in your design needs its own film. For example a three color print will need three screens and three films.

#5: Line up your film on the back of your now dried screen. You can secure it with clear tape. If you are printing a multi color job try to line up each film in the same general area on all the screens. This will help when you are trying to line the colors up on the press. The light source is used to "burn" the image into the emulsion. The emulsion where that the film is not covering will now harden. All exposure units are different so you'll have to figure out the right amount of time to leave the light on but most good units will have about a one minute burn time.

#6: Bring your screen to your wash out area. You can use one of those fancy wash out booths with the pressurized hoses, a power washer or any old regular garden hose will work. Hit the screen all over until your design washes out.

#7: You basically just made a stencil for your artwork. The ink will now pass through anywhere that washed out clear.

#8: Let your screen dry, tape up the edges.... and you are ready to print.

Hope that was slightly educational. All that is why the screen set ups apply to your job. Its not as easy as printing out a design and ironing it on to a shirt. That process is quick, but they look like shit and will eventually fall off in the wash. If you correctly make a screen and use the right kind of ink you have a better chance of the shirt falling apart before the ink ever comes off.