Screen printing technology offers advantages such as ease of operation, low cost, and versatile application, making it a key method for conventional textile printing. Based on the machinery used, it is primarily categorized into three types: manual screen printing, flat-screen printing, and rotary screen printing.
Manual Screen Printing
Manual screen printing was highly prevalent in the 1920s and remains widely used today. Until the mid-1950s-when modern technology introduced automation to the process-manual screen printing was the only method available. Commercial manual screen printing is performed on long tables (up to 60 yards in length) at a production speed of 50–90 yards per hour. It is also extensively used for printing on pre-cut fabric items, such as beach towels, printed aprons, draperies, and shower curtains. Due to benefits like unlimited color registration, crisp pattern definition, and minimal fabric damage, manual screen printing remains relevant; it is particularly well-suited for small-batch, multi-variety production and for printing on lightweight or delicate fabrics.
Flat-Screen Printing (Automatic Screen Printing)
Flat-screen printing, also known as automatic screen printing, saw further development in the mid-1960s. While it operates on the same principle as manual screen printing, the process is automated, resulting in faster printing speeds. Fabric is transported via a wide rubber belt to the screen station; it pauses beneath the screen for the squeegee operation before moving to the next screen frame, achieving a production speed of approximately 500 yards per hour. Flat-screen printing is widely used in Asian countries. Its screen-making costs are lower than those of rotary screen printing, and it accommodates patterns with long repeats. Additionally, the extended contact time between the fabric and the screen makes it particularly suitable for printing on fabrics like terry cloth, as well as for small-batch, intricate printing. In recent years, the rise in small-batch orders has led to an upward trend in the use of flat-screen printing. Furthermore, equipment manufacturers have introduced combination printing machines that allow for the simultaneous or interchangeable use of rotary and flat screens, thereby enhancing production flexibility.
Rotary Screen Printing
Rotary screen printing is currently the most widely used screen printing method. Since its introduction in the 1960s, it has developed rapidly, accounting for nearly 60% of total fabric printing volume-and over 90% in Western Europe. It is a continuous process in which the fabric is conveyed on a wide rubber belt beneath continuously rotating cylindrical screens; it offers the fastest production speeds, exceeding 3,500 yards per hour. The process utilizes seamless, perforated metal or plastic screens; with screen circumferences exceeding 40 inches, the maximum pattern repeat size also exceeds 40 inches. Rotary screen printing machines capable of printing more than 20 colors have also been manufactured. Characterized by high printing speeds and a high degree of automation, the method is well-suited for large-scale production.