Mesh Size in Screen Printing

What is Mesh Size

In the screen printing industry, mesh size is a critical parameter that directly impacts print quality, ink coverage, and image detail. Mesh size refers to the number of threads per square inch in a screen. For example, a 110 mesh screen has 110 threads intersecting per square inch. Higher mesh counts have finer threads and smaller openings, while lower mesh counts have coarser threads and larger openings.

Factors Influencing Mesh Size Selection

Choosing the right mesh size involves several key considerations:

Image Detail Level

The level of detail in the design is a primary factor in selecting mesh size. Highly detailed images require high mesh count screens. Using a low mesh count screen for intricate designs can cause fine dots and lines to pass through the larger openings, resulting in a loss of image detail. For instance, four-color process or simulated process printing typically requires a mesh count of 305 or higher to ensure fine halftone dots are accurately retained and exposed.

Conversely, for designs with minimal detail, such as solid color blocks or text, using a high mesh count screen may lead to insufficient ink coverage, impacting print quality.

Ink Type and Viscosity

The type and viscosity of the ink significantly influence mesh size selection:

• Water-based inks: These inks are thinner and typically require high mesh count screens (230 or higher). Using a low mesh count screen with water-based inks may cause excessive penetration, resulting in blurred images.
• Plastisol inks: These thicker inks, especially white plastisol, often require lower mesh count screens (110 or 156). High mesh count screens can make printing thick inks challenging, potentially requiring multiple passes to achieve the desired ink layer thickness.
• Glitter or metallic inks: These inks contain large glitter or metallic particles, necessitating very low mesh count screens (38–86). For example, gold glitter ink (e.g., FN-INK Gold) can pass through an 86 mesh screen, while larger particle glitter inks may require even lower mesh counts.

Substrate Type

The type of printing substrate also affects mesh size selection:

• Textiles: When printing on T-shirts or other fabrics, consider the fabric’s texture and ink absorption. Mesh counts of 110–156 are suitable for most textile printing.
• Smooth surfaces: For printing on paper, plastic, or metal, higher mesh counts (230–305) can be used to achieve finer details.
• Rough surfaces: Rough or porous surfaces may require lower mesh count screens to ensure adequate ink coverage.

Common Mesh Sizes and Their Applications

Different mesh sizes suit various printing applications. Below are the most common mesh sizes and their typical uses:

Low Mesh Count (38–86)

Low mesh count screens are ideal for special effect printing, particularly with inks containing large particles:

• 38 mesh: Suitable for the largest glitter ink particles, allowing them to pass through the screen fully.
• 64 mesh: Ideal for medium-sized glitter ink particles.
• 86 mesh: Used for smaller glitter or metallic inks.

Pro Tip: When using large-particle inks, adding a curable reducer can help the ink flow more smoothly through the screen. For example, adding a curable reducer to FN-INK Gold allows it to pass through up to a 230 mesh screen.

Medium Mesh Count (110–156)

This is the most commonly used mesh range for standard printing tasks:

• 110 mesh: Deposits a thicker ink layer, ideal for printing solid color blocks, text, and simple patterns. It’s also perfect for underbase printing, as it achieves a thick ink layer in a single pass, improving efficiency.
• 156 mesh: Offers moderate ink deposition while maintaining good detail. This is a popular choice for many printers due to its balance between ink coverage and detail retention.

High Mesh Count (200–305)

High mesh count screens are used for prints requiring fine details:

• 230 mesh: Retains larger halftone dots, suitable for graphic inks, solvent-based inks, and water-based inks. Prints with this mesh count often have a softer hand feel due to less ink passing through.
• 305 mesh: Ideal for highly detailed printing, such as four-color process or simulated process printing. It accurately retains fine halftone dots but deposits less ink, potentially requiring multiple passes for optimal color saturation.

Ultra-High Mesh Count (355–400)

These extremely high mesh count screens are used for specialized applications:

• 355, 380, and 400 mesh: Primarily used for UV ink graphic printing on signs, banners, or CDs. UV inks are very thin, and high mesh counts help automated presses control ink flow.

Mesh Types: Thin Thread vs. Standard Thread

In addition to mesh count, the type of screen thread is a key consideration:

Hi-DRO (Thin Thread)

Hi-DRO, or thin thread screens, have long been the standard for water-based ink printing due to:

• Finer thread profiles and larger openings, allowing easier ink flow.
• Reduced screen clogging.
• Better retention and printing of high-level details.
• Less restriction on emulsion and ink due to smaller thread space.

Recently, more print shops have started using Hi-DRO screens for plastisol ink printing, especially for underbase layers.

Hi-TEX (Standard Thread)

Hi-TEX, or standard thread screens, offer:

• Thicker threads than Hi-DRO.
• Higher tension tolerance.
• Greater resistance to tearing or breaking during printing.
• A mainstay in plastisol textile printing for decades.

White vs. Yellow Screens

Screen color also impacts printing results:

White Screens

• Faster emulsion exposure.
• White threads may cause light scattering, potentially leading to detail loss or blurred edges.
• Typically used with low mesh count screens requiring thicker emulsion coatings to speed up exposure.

Yellow Screens

• Minimal light scattering, preserving image detail.
• Approximately 30% longer exposure time compared to white screens.
• Ideal for prints requiring high-precision detail retention.

Screen Frame Types

Wooden Frames

Wooden frames are ideal for beginners and cost-conscious printers:

• Affordable.
• Suitable for permanent or long-term designs.
• To extend lifespan, use pressure washing and limited dip tank cleaning; avoid soaking.

Aluminum Frames

Aluminum frames offer greater durability and stability:

• Resistant to warping when exposed to water, unlike wooden frames.
• Maintain flatness over thousands of prints.
• Can be remeshed multiple times.
• Lightweight, reducing shipping costs.
• Ideal for printers aiming to enhance studio performance.

Self-Tensioning Frames (ECO Frames)

Self-tensioning frames allow printers to install screens themselves:

• Enable quick production recovery.
• Allow rapid mesh count changes between orders.
• Save studio space.
• Suitable for experienced printers seeking new challenges.

Mesh Size and Exposure Time Relationship

Different mesh sizes affect emulsion usage, which in turn impacts exposure time:

• Low mesh count screens (e.g., 110) hold more emulsion due to larger openings.
• High mesh count screens (e.g., 305) hold less emulsion.
• Thin thread screens hold less emulsion than standard thread screens, resulting in shorter exposure times.
• Mesh size differences can lead to a 5–10% variation in exposure time.

Mesh Size to Micron Conversion Chart

For precise understanding, here’s a conversion table for common mesh counts, microns, and inches:

Note: Screens above 325–400 mesh are typically described in microns only.

Practical Considerations for Mesh Size

Choosing the right mesh size in practice requires balancing multiple factors:

Balancing Efficiency and Quality

• Low mesh count screens allow more ink to pass, reducing print passes and increasing efficiency.
• High mesh count screens provide finer details but may require multiple passes for desired color saturation.
• In production, find a balance between efficiency and quality.

Hand Feel Considerations

• High mesh count screens produce prints with a softer hand feel due to less ink deposition.
• Low mesh count screens may result in a stiffer hand feel but deliver vibrant, saturated colors.
• Select mesh count based on client preferences for the final product’s feel.

Ink Coverage and Opacity

• Low mesh count screens offer better ink coverage, ideal for printing on dark substrates.
• High mesh count screens may result in slightly transparent or faded prints.
• For dark T-shirts, use a low mesh count screen for a white underbase, followed by a higher mesh count for colored designs.

Frequently Asked Questions

How do I determine the mesh size needed for my design?

Evaluate the design’s detail level and ink type. For fine text, lines, or halftones, choose a higher mesh count (200–305). For solid color blocks or simple patterns, use a medium mesh count (110–156). Specialty inks typically require low mesh counts (38–86).

Why is my detailed image losing detail during printing?

You may be using a mesh count that’s too low. Fine details can pass through larger openings, failing to print correctly. Try a higher mesh count, such as 230 or 305.

Why is my white ink coverage insufficient?

White plastisol ink is thick and may struggle to pass through high mesh count screens. Use a 110 or 156 mesh screen or add a curable reducer to improve ink flow.

How does mesh size relate to emulsion thickness?

Low mesh count screens (e.g., 110) hold more emulsion due to larger openings, while high mesh count screens (e.g., 305) hold less. This affects exposure time, typically varying by 5–10%.

Should I choose white or yellow screens?

It depends on your needs. For faster exposure, use white screens. For high-precision detail retention, use yellow screens, but expect a 30% longer exposure time.