Screen Printing FAQ — Everything You Need to Know
Screen Printing FAQ — Your Questions Answered
Screen printing is one of the most established decoration methods in the apparel industry. If you’re considering screen printing for your custom t-shirts, spirit wear, or event apparel, here are honest answers to the questions customers ask most.
Main Street Shirt Company has been screen printing in Illinois since 1998. We run a 6-color, 8-station automatic press plus a manual press — all production is done in-house.
The Basics
What is screen printing?
Screen printing is a process where ink is pushed through a mesh screen (stencil) onto a garment. Each color in the design requires its own separate screen. Ink is applied one color at a time, then heat-cured to bond it to the fabric. The result is a durable, vibrant print that holds up well through repeated washing.
How many shirts do you need to screen print?
Most shops require a minimum of 12 to 24 pieces per design. At Main Street Shirt Company, we work with customers to find the right threshold based on the number of colors and garment type. The reason for minimums is setup cost: making screens, mixing ink, and setting up the press takes significant time regardless of how many shirts you print. That setup cost becomes economical once it’s spread across enough pieces.
Why does screen printing require minimum quantities?
Because the setup work is the same whether you print 10 shirts or 500. Each color requires a separate screen, which must be prepared, coated, exposed, washed out, and mounted on the press. That process typically takes 30–60 minutes per color before the first shirt is printed. On a 100-shirt run, the setup cost is a small fraction of the total. On a 6-shirt run, the setup cost makes the per-shirt price prohibitive. For small quantities with no minimums, DTF printing is usually the better choice.
What is the maximum number of colors in a screen printed design?
Our automatic press runs up to 6 colors. Designs with 7 or more colors are generally better suited for DTF printing, which handles unlimited colors at no additional cost. Most spirit wear and team apparel designs work well within 1–4 colors.
Ink and Print Quality
What type of ink is used in screen printing?
The most common ink type is plastisol, a PVC-based ink that sits on top of the fabric and produces vibrant, opaque colors. Plastisol is extremely durable and is the industry standard for most commercial t-shirt printing. We also use water-based inks for specialty applications where a softer hand feel is desired.
How long does screen printing last?
When properly cured and cared for, screen printed plastisol ink can last for the life of the garment. It is one of the most durable decoration methods available. The print is significantly more resistant to fading and cracking than most heat transfer methods.
Does screen printing crack or peel?
Properly cured plastisol screen printing does not crack or peel under normal wear and wash conditions. Cracking in screen printing is almost always caused by undercuring the ink during production — a quality control issue. We run all garments through a conveyor dryer to ensure proper cure temperature.
Can you print on dark shirts?
Yes. Printing on dark garments requires an underbase — a white ink layer printed first, which allows subsequent colors to show correctly on dark fabric. This adds one screen to the setup and slightly affects pricing, but the result is clean, vibrant color on any dark garment.
Can you print white ink?
Yes. White plastisol ink is a standard screen printing ink. On dark garments, white ink is commonly used as both an underbase and as a design color.
Pricing
How is screen printing priced?
Screen printing pricing is based on four main factors: (1) quantity of garments, (2) number of ink colors, (3) number of print locations, and (4) the cost of the blank garment. More pieces = lower per-unit price. Fewer colors = lower setup cost. Contact us at info@mainstreetshirtcompany.com for a quote based on your specific project.
Is screen printing cheaper than DTF for large orders?
Yes — generally. For orders of 24 pieces or more with a design that uses 1–4 colors, screen printing will typically be more cost-effective than DTF. The per-unit cost of screen printing decreases significantly as quantity increases. DTF has a flat cost per print area regardless of quantity, which makes it competitive for small runs but less efficient for large ones.
Does it cost more to print on the back of a shirt?
Yes. Each print location (front, back, sleeve) is priced separately because each location requires its own screen setup and print pass. A two-location print (front + back) will cost more than a single-location print.
Artwork and Files
What file type do I need for screen printing?
Vector files are best: AI (Adobe Illustrator), EPS, or SVG. These files can be scaled without quality loss and allow colors to be accurately separated for screen production. High-resolution raster files (PNG or TIFF at 300 DPI or higher at print size) can also work for simpler designs. Low-resolution images from websites, Facebook, or screenshots cannot be used for screen printing.
What if I don’t have a vector file?
Our in-house design team can redraw or recreate artwork in vector format. Simple redraws are often included at no charge. Complex original artwork may involve a design fee. Contact us to discuss your artwork situation before assuming your file won’t work.
Can you print copyrighted logos or trademarked designs?
No. We cannot print officially licensed logos (NFL, NBA, NCAA, Disney, etc.) without a licensing agreement. We can print school mascots and logos for school-affiliated orders. If you’re unsure whether your artwork involves a trademark issue, ask us before placing the order.
How many colors is my design?
Each distinct ink color counts as one color — including white if printing on a dark garment. A design that appears to have gradients or photographic detail may actually require separating into many spot colors, or it may need to be converted to a halftone technique. If your design is complex, send it to us and we’ll tell you how many screens it requires.
Garments and Fabrics
What fabrics can be screen printed?
Screen printing works best on 100% cotton and cotton/polyester blends. High-polyester fabrics (above 65%) can cause dye migration — where the dye in the shirt bleeds into the ink — which can affect color accuracy. For performance fabrics and high-polyester garments, DTF printing is often a better choice because it is not affected by dye migration.
What shirt brands do you recommend for screen printing?
For most orders, we recommend Gildan Softstyle (64000) for t-shirts and Gildan Heavy Blend (18000/18500) for hoodies and crewnecks. These garments offer excellent printability, consistent sizing, and a price point that works for most budgets. For premium orders, Bella Canvas 3001c and Comfort Colors 1717 are excellent choices with a softer hand feel and more fashion-forward fit.
Ordering and Turnaround
How long does screen printing take?
Standard production turnaround at Main Street Shirt Company is 2 weeks or less from approved artwork. Rush production may be available for qualifying orders. The timeline starts once artwork is approved — not when the order is placed.
Can I order different sizes and still get the screen printing price?
Yes. Sizing mix (S, M, L, XL, 2XL, etc.) within a single design run is standard and does not affect the per-unit print price. The total quantity across all sizes determines the pricing tier.
Can I mix shirt colors in one order?
Sometimes. Mixing garment colors within one run can complicate production — especially if some are light shirts and some are dark (because dark shirts require an underbase and light shirts do not). Contact us to discuss whether your specific order can be accommodated efficiently.
Screen Printing vs. Other Methods
When should I use DTF instead of screen printing?
Use DTF when: you need fewer than 12 pieces, your design uses more than 6 colors or has photographic detail, you need individual names or numbers on each piece, or your garment is a polyester or performance fabric. See our full DTF vs. Screen Printing comparison.
When should I use embroidery instead of screen printing?
Use embroidery when: you’re printing on a polo, cap, jacket, or bag, you want a premium dimensional look, or the item is a professional/workwear piece. Screen printing is generally not used on structured caps or thick outerwear. See our Embroidery FAQ.
Ready to get started? Contact Main Street Shirt Company at info@mainstreetshirtcompany.com for a quote on your screen printing project.