Screen Printing Inks Guide: Water-Based, Plastisol, Solvent & Epoxy Technical Specifications

Modern screen printing requires in-depth knowledge of inks and their interactions with different mesh types. This technical guide explores in detail the four main ink categories, providing:

Complete technical specifications
Recommended meshes for each application
Optimal printing parameters
Real-world use cases with concrete examples
Solutions to common problems

1. Water-Based Inks

Technical Characteristics

Water-based inks represent the ecological choice for printing on natural fabrics. Their advanced formulation includes:

Water base (60-75%): Demineralized water with low heavy metal content
Pigments (15-25%): Ultra-fine dispersions with 0.2-0.8 micron particle size
Binders (12-18%): Modified acrylic-vinyl copolymers
Additives (5-8%): Wetting agents, retarders, and viscosity regulators

Recommended Meshes

Processing Type	Mesh Count	Thread Material	Opening	Deposit Thickness
Base printing on cotton	43-80T	Polyester	75-100μm	12-18μm
Graphic details	100-140T	Calendered polyester	45-60μm	8-12μm
Resist printing	62-71T	HD polyester	110-130μm	20-30μm

Practical Application Fields

Sustainable fashion: Organic cotton T-shirts with GOTS certification, where soft hand feel is crucial. Example: "eco-print" collections for premium brands.

Merchandising: Printing on raw canvas bags for corporate events, with special attention to fabric breathability.

Home decor: Cushions and home textiles requiring repeated 60°C washes without color loss.

"For our high-fashion productions on linen and hemp, we exclusively use water-based inks with 90T HD mesh. This allows exceptional color rendering while maintaining the fabric's natural breathability."
— Elena Rossi, Technical Director @EcoTextilePrint

Common Problems and Solutions

Problem: Mesh clogging during long runs

Cause: Premature ink drying in holes

Solutions:

Add 3-5% specific wetting agent
Use polyurethane squeegees with rounded edge
Maintain ambient humidity >55% RH
Prefer meshes with anti-adhesive treatment

2. Plastisol Inks

Chemical Composition

Plastisol is the most versatile printing system for apparel, composed of:

PVC resin (28-35%): Plasticized with low molecular weight
Plasticizers (45-55%): Phthalates or non-phthalate substitutes (DINCH, DOTP)
Pigments (12-22%): Concentrates with high tinting strength
Additives (5-10%): Thinners, opacifiers, retarders

Optimal Mesh Selection

Plastisol Type	Recommended Meshes	Thread Diameter	Ink Viscosity	Typical Applications
Standard	43-140T	34-40μm	40,000-60,000 cps	Cotton/poly T-shirts
High Density	62-77T	48-55μm	80,000-120,000 cps	3D effects
Soft Hand	140-160T	27-34μm	25,000-35,000 cps	Soft hand printing
Glow in the Dark	90-110T	40-48μm	50,000-70,000 cps	Safety apparel

Industrial Application Examples

Sportswear: Printing on technical polyester with 140T mesh and high-elasticity plastisol (300% stretch). Resistant to frequent 40°C washes.

Promotional merchandise: Hoodie printing with high-density (62T mesh) to create relief effects surviving over 50 industrial washes.

Work uniforms: Using 110T mesh with high-coverage plastisol to ensure visibility and durability on heavy fabrics like twill.

"In professional sportswear production, we combine 140T mesh with silicone plastisol to achieve elastic prints maintaining chromatic integrity even after repeated stretching and aggressive washing."
— Marco Bianchi, R&D Manager @SportWearTech

Optimal Curing Parameters

Polymerization requires attention to three key factors:

Peak temperature: 160-170°C (320-338°F) at ink core
Exposure time: 90-120 seconds at target temperature
Thermal ramp: Don't exceed 10°C/min to avoid thermal shock

Important Warnings

Under-curing causes:

Poor wash resistance
Plasticizer migration
Loss of elasticity

Over-curing causes:

Print yellowing
Excessive stiffness
Thermal fiber degradation

3. Solvent-Based Inks

Chemical Formulations

Solvent inks differ by the nature of solvents used:

Solvent Type	Evaporation Rate	Surface Tension	Target Substrates	Optimal Meshes
Ethyl acetate	4.1	23.9 dyn/cm	Rigid PVC	120-140T
MEK	6.3	24.6 dyn/cm	Metals	140-160T
Isopropanol	2.4	21.7 dyn/cm	Polypropylene	90-110T
Glycol ethers	0.2	28.3 dyn/cm	Glass	77-90T

Specialized Application Fields

Electronics: Printing conductive circuits on plastic substrates with 160T mesh and polar solvent-based inks to ensure adhesion on polycarbonate.

Automotive: Car interior decals with UV and thermal shock-resistant inks (-40°C/+85°C), applied with 140T mesh.

Packaging: Printing on pharmaceutical blisters with FDA-approved solvent inks, using 150-180T mesh for precise details.

"For printing on ABS electronic components, we use solvent inks with 160T stainless steel mesh. This allows lines thinner than 100μm with resistance to cleaning solvents."
— Eng. Paolo Verdi, Production Manager @ElectroPrintSolutions

Safety Considerations

Solvent use requires strict precautions:

Ventilation: Minimum 15 air changes/hour with ATEX extractors
PPE: ABEK1P3 filter masks, nitrile gloves
Storage: Ventilated cabinets with explosion-proof protection
Disposal: Separate collection with authorized operators

4. Epoxy Inks

Two-Component Technology

Epoxy inks offer extreme performance thanks to:

Component A: Modified epoxy resin with mineral fillers (40-60%)
Component B: Polyamide or amine crosslinking agent (10-20%)
Additives: Wetting agents, accelerators, flow modifiers (5-10%)

Mesh Selection for Critical Applications

Substrate	Recommended Mesh	Material	Thickness	Application Example
Steel	90-120T	Stainless steel	55-75μm	Industrial panels
Aluminum	120-140T	HD polyester	40-60μm	Aerospace components
Glass	77-90T	Nylon	70-90μm	Protective screens
Ceramics	140-160T	Fine polyester	30-50μm	Decorative tiles

Advanced Industrial Applications

Aerospace: Marking light alloy components with epoxy inks resistant to -60°C/+200°C, using 140T steel mesh.

Medical: Printing on surgical instruments with biocompatible, sterilizable inks, applied with 160T mesh.

Electronics: Screen printing PCBs with conductive epoxies, using 120T mesh for 25-35μm thick deposits.

"In marine engine component production, we use thermosetting epoxies with 90T steel mesh. Prints withstand saltwater, UV, and abrasion for over 10 years in extreme conditions."
— Dr. Roberto Neri, Materials Engineer @MarineTech