Screen printing is a remarkable craft that enables you to transfer designs onto almost any material. It perfectly works with T-shirts, posters, and even wooden signs. The process of screen printing begins with one essential component: the stencil.
The stencil serves as a mask, blocking the screen mesh in specific areas. That allows ink to pass through where the design requires ink. The most important part of this craft is to create a precise stencil. The quality of your final print depends on the quality of your stencil.
If you want to learn how to screen print at home or at scale, this post is for you. In this post, we will cover three proven methods of making silk screen stencils. Learn about these techniques and pick one that is compatible with your skill level and suits your project requirements.
Method 1: The Cut Stencil Approach
For those wondering how to screen print at home, this is the easiest and fastest way to do the job. You need minimal special tools for the cut stencil method. This method is suitable for DIY silk screen printing and artwork with graphic shapes, bold lines, or block text.
The cut stencil method essentially involves cutting your design out of a thin material. Once done, secure the material to the screen mesh. The ink cannot pass through the covered sections.
Materials Needed
To print a stencil, first, you need a clean screen printing frame. Get a squeegee and the ink of your choice. For the stencil, there are several options.
Heavy-weight paper or thin cardstock works for simple, one-time prints. If you want to reuse the stencil, get contact paper or adhesive vinyl. The adhesive will prevent ink from bleeding under the edges, so it is crucial.
For the cutting tool, get a sharp craft knife. You also need a self-healing cutting mat. To ensure precision on straight edges, use a metal ruler. To find all these together, you can look for a DIY silk screen kit online.
Understand Positive and Negative Space
The positive space is the area that you cut out and remove. This is where the ink will print on your paper or shirt. The material that is left behind will remain on the screen, and it is the negative space. In other words, the negative space blocks the ink flow entirely.
How to Cut Your Stencil by Hand
This is a pretty straightforward way to make a silk screen at home. Prepare the design first. Print or draw the material directly onto the stencil material. If you are using silk screen printing paper, consider taping it to the mat. And if you are using vinyl, you can tape it onto the backing paper.
Pro tip: Always trace the reverse image if the design includes text. By doing so, you can ensure that the final print will read correctly on the fabric.
As you begin cutting, follow the design lines with your sharp craft knife. Make sure the cuts are precise. Accidental cuts and jagged lines will ruin your print.
Then weed the design, removing the pieces of material. The ink will pass through these removed sections.
Apply the Stencil to the Screen
Once weeding is done, find a flat surface and place the stencil on it, with the adhesive side facing up. Place the screen frame down onto the silk screen stencil. Press firmly to make sure the contact is even.
Then flip the screen over. If you used vinyl for vinyl silkscreen, peel away the backing paper. At this stage, the vinyl should be adhered to the mesh. For paper stencil printing, the application process is different. The cutout is to be laid on the print surface first. Then hold the edges down with ink and print.
The final step of the process is taping. For this, you can use special screen tape or commonly used masking tape. Make sure all exposed areas of the screen mesh are blocked out. Pay particular attention to the internal borders of the frame. Note that the ink will pass through any uncovered mesh. The quality of the final print depends on this step, so be careful about it.
Using Machine-cut Vinyl
Use a vinyl cutting machine if you want to produce complex silk screen stencils at scale. Professionals often use tools like Silhouette or Cricut, which offer precision. If you are running a small business, this method is for you.
In this method, the first step is to create the art digitally, with graphic software. Then you have to export the file to the cutting machine and feed adhesive vinyl into the cutter. The machine traces and cuts the entire design precisely.
After that, you have to perform the wedding. Remove the vinyl pieces that make up the printed area. The blockout is the vinyl pieces that remain after this. Then, put the finished stencil on the screen mesh. For this part, the technique is the same as that of the hand-cut method.
Make sure the vinyl is flat, smooth, and secured tightly. Machine cutting offers great accuracy and leaves the reusable silk screen stencils more durable.
Method 2: The Blockout Method
If you want a hand-drawn, organic look, the blockout method is suitable for you. It is also called the drawing fluid method. With expressive brushstrokes and unique textures, this technique is very artistic. This method basically involves painting the mask directly onto the mesh.
Supplies Needed
This method requires two chemical components: drawing fluid and screen filler. They are usually available together in a kit. The drawing fluid is temporary; it washes away easily. During printing, the permanent blockout is the screen filler.
You also need a few paintbrushes of various sizes. Make sure you have a water source ready for the final washout.
How Does It Work?
First, draw the design onto the screen mesh. For this step, use the drawing fluid. This is the part that prints. The mesh is covered with this fluid. Then, the mesh will be open for ink flow. It serves as a temporary resistor. The bright, contrasting color of the drawing fluid makes it easy to see the design.
Move to the next step when the drawing fluid is completely dry. Apply the screen filler over the entire screen, including the dried drawing fluid. Typically, the screen filler is acrylic-based or lacquer-based. It serves as a permanent blocker on the mesh. Use a brush or squeegee to apply a thin and even coat on both sides of the screen.
Leave the screen filler to dry fully. Read the manufacturer’s instructions to learn the exact drying time.
Washing Out the Design
Gently spray the screen with cold water. The water will dissolve the drawing fluid. As the water carries the fluid away, the clear mesh is left behind. Gradually, it will reveal the open stencil area.
The filler keeps the rest of the screen blocked. Now it should be resistant to ink. If there are any pinholes, touch them up. To do that, you may need a brush and a little more screen filler. Also, make sure you tape the frame’s internal borders. This technique is great for preserving the quality of your hand-painted line.
Method 3: Photo Emulsion
This is the industry standard for making a stencil for a silkscreen print. Professionals adopt this method, in part because it transfers intricate details and photographic images. The technique involves using a UV light-sensitive chemical coating. If you want a complex design, the photo emulsion technique can be a powerful method.
Essential Supplies
For custom screen printing stencils, you need a controlled environment for implementing the photo emulsion technique. A completely dark room is preferable, but there can be a yellow safe light. You must avoid normal white light because it will prematurely expose the chemicals.
The method requires mixed photo emulsion and its sensitizer. A scoop coater is needed for applying the emulsion evenly. Your design requires a transparency film, also known as a film positive. Also, have a strong source of UV light. For the best results, use specialized lamps or an exposure unit. Also, you need a high-pressure water source for the final washout.
Coating and Drying the Mesh
To begin with, your screen must be flawlessly clean. Use a commercial degreaser to degrease the mesh. It will also help the emulsion bond correctly.
Then mix your photo emulsion in the darkroom. Apply a thin, smooth layer with the scoop coater. For the optimal results, both sides of the screen should be coated. Sharp details depend on consistent thickness.
Allow the screen to dry completely. Keep it horizontally in the dark room. Usually, drying takes a couple of hours. Completely avoid exposure to any white light during this time.
Preparing the Film Positive
Prepare your design while the screen dries. To create the film, print the artwork in opaque black ink onto the transparency film. The black areas will block the UV light and protect the emulsion underneath. The ink will pass through the mesh in these protected areas.
Exposing the Stencil
Place the film positive on the screen when it is bone dry. Tightly secure the film against the mesh. For this, you can use a sheet of clear plastic or glass. For a sharp image, the contact must be tight.
Now you have to use the powerful UV light source. Expose the screen to the light source. The light hardens the exposed emulsion, permanently bonding to the mesh fibers. The light cannot pass through the opaque black areas of the film positive. As a result, under these areas, the emulsion remains soft.
Note that the exposure time should be precise. The exact time should depend on the power of the light source and the type of emulsion. Consider performing test exposures. The exposure time should not be too short or too long.
Washing Out and Curing
Gently spray the screen with cold water. Spray on both sides of the mesh. The unexposed emulsion will dissolve. Keep washing until the image is sharp and clear.
Finally, expose the dry screen to UV light again. It will harden the parts of the emulsion that may be under-exposed. It will also improve the durability of the screen.
Clean It Up
Proper cleanup is necessary because it protects your screen frame and allows you to reuse the mesh.
Cleaning the paper and vinyl stencils is quick and easy. Peel the material, tape away the printing, and wash all the excess ink residue.
If you are adopting the blockout method, you will need a dedicated screen filler remover. Choose a product that is compatible with the filler type you are using.
A chemical emulsion remover is required to remove a durable photo emulsion stencil. The remover penetrates the hardened emulsion, and you use a pressure washer to remove the stencil material from the mesh.
Wrapping Up
When it comes to custom silk screen printing, the most important part is creating a stencil. While there are multiple methods, choose one depending on your design, tools, and experience level.
Each of the three approaches discussed in this article has its own advantages. Regardless of the method you follow, the success of your project will depend on careful preparation and attention to detail.
