T-Shirt Print Guide
Learn how to prepare your t-shirt designs for screen printing. From color separations to ink layering, this guide covers everything you need to produce professional-quality prints.
Screen Printing Basics
Screen printing works by pushing ink through a mesh stencil onto fabric. Each color requires its own screen (stencil), so designs are separated into individual color layers called 'separations'.
Color Separation
Your design is split into individual color layers. Each layer becomes a separate screen. Fewer colors = fewer screens = lower cost.
Registration
Each color screen must align perfectly with the others. Our builder generates sharp, high-contrast masks that make registration easy.
Ink Order
Colors are printed lightest to darkest. On dark shirts, a white underbase is printed first so colors remain vibrant.
From Design to Print
Follow these steps to go from a digital design to a finished screen-printed t-shirt.
Design Your Artwork
Use the T-Shirt Builder to upload your image. The builder automatically detects colors and generates a screen-print preview. Adjust the number of ink colors (1-5), customize the palette, and position your design.
Download Color Separations
Each ink color produces a separate black-and-white mask — your 'film positive'. These are high-contrast (pure black on white) with no blurry edges, ready to expose onto screens.
Expose Your Screens
Print each separation onto transparency film. Coat your screen mesh with photo emulsion, place the film on top, and expose to UV light. Wash out the unexposed areas to reveal your stencil.
Mix Your Inks
Match your ink colors to the hex values shown in the builder. Use plastisol ink for durability or water-based ink for a softer hand feel. On dark garments, mix a white underbase ink.
Print & Cure
Register each screen on your press. Print lightest colors first, flash-cure between layers, then print the final color. Cure the finished print at 160°C (320°F) for 60-90 seconds.
Print Specifications
Standard specifications for screen printing on garments.
Print Area
| Area | Size | Notes |
|---|---|---|
| Front Chest (Standard) | 30 × 40 cm | Centered, 7 cm below collar |
| Left Chest (Pocket) | 10 × 10 cm | Left chest, small logo placement |
| Full Back | 30 × 40 cm | Centered, 7 cm below collar seam |
| Sleeve | 10 × 13 cm | Outer upper arm area |
Mesh Count
| Use | Mesh | Notes |
|---|---|---|
| Fine Text & Detail | 230-305 threads/inch | Thin lines, small text, halftones |
| General Graphics | 156-200 threads/inch | Most designs, logos, multi-color |
| White Underbase | 110-156 threads/inch | Heavy ink deposit for opacity on dark shirts |
| Specialty Inks | 60-110 threads/inch | Glitter, puff, metallic inks |
Materials & Equipment
Essential supplies for screen printing at home or in a small studio.
Screens
Aluminum frames with polyester mesh. 20×24 inch is standard for t-shirts. One screen per color.
Photo Emulsion
Light-sensitive coating for screens. Diazo-based for beginners. Apply in a dark room, dry horizontally.
Screen Printing Ink
Plastisol (heat-cured, opaque) or water-based (air-dry, softer). Plastisol is easier for beginners.
Squeegee
70-75 durometer for general use. Width should be 2-3 cm wider than your design.
Transparency Film
Inkjet transparency sheets for printing your separations. Use 'darkest' print setting for maximum opacity.
Screen Press
Single-color: simple hinge clamp. Multi-color: rotary press with micro-registration. DIY options work for small runs.
Common Mistakes to Avoid
My colors are printing too transparent on dark shirts
You need a white underbase layer. Print white ink first, flash-cure it, then print your colors on top. This gives the colors something opaque to sit on.
The edges of my print are blurry
Your film positive needs to be 100% black with no gradients. Our builder uses hard thresholds (0 or 255) to ensure sharp masks. Make sure your printer is set to maximum ink density.
Colors are not aligning between layers
Registration is critical. Use registration marks on each separation. A rotary press with micro-adjust is recommended for 3+ color jobs.
How many shirts can I print with one screen?
A properly exposed and cared-for screen can last 500-1000+ prints. Reclaim screens with emulsion remover to reuse them.
What's the minimum order for screen printing to be cost-effective?
Due to setup time (exposing screens, mixing inks), screen printing becomes cost-effective at 25+ units. For smaller runs, consider DTG or heat transfer.
Ready to Create?
Design your custom t-shirt with our 3D builder. Upload artwork, customize colors, and preview your screen-printed design in real-time.
Open T-Shirt Builder