How to create a screen using emulsion

Where does exposure fit in the screen printing process?

What emulsion should I use?

How long can I keep emulsion?

How do you get rid of pin holes?

How long should I dry my screen?

 

Let’s go back to basics. Screen printing is also a stencil method of print making in which a design is imposed on a screen of polyester or other fine mesh, with blank areas coated with an impermeable substance, and ink is forced into the mesh openings of the mesh by the fill blade or squeegee and onto the printing surface during the squeegee stroke.

Emulsion is the means of making impermeable substance. Light sensitive, thick liquid which coats the screen. When the screen is exposed the emulsion hardens and unexposed areas drop out to leave the stencil.

So you have your positive artwork

Making Your Artwork Positive.

Making Your Artwork Positive.

Now this process is one of the most tricky in screen printing and needs to be done thoroughly and carefully. Never skip on any step especially drying.

The first step is to degrease your screen

It is very important to degrease the screen prior to coating the screen with emulsion and exposing the artwork. A screen that is not degreased will have problems exposing and increase the chance of pinholes, the emulsion will not adhere to the screen properly and might washout before the image can be seen. The emulsion could also not wash out at all. Make sure you let it dry thoroughly before you coat it with emulsion.

Choosing your emulsion

There are many emulsions on the market and every printer will have their preferred type and brand. Some emulsions come pre sensitised and ready for use and some will need mixing. Our emulsion is a 2 part emulsion, its comes with sensitizer.

Shelf life is different depending on when the sensitizer is added . Separately both parts can last from 12-24 months. Once mixed the emulsion lasts 6-8 weeks (its life can be prolonged slightly if it is stored in a cold place, like the fridge).
Always make sure you have chosen the right emulsion if you are using Plastisol inks / Solvent inks you need a Solvent resistant emulsion like Ulano Proclaim or if you are using Waterbased inks you need a water resistant emulsion like Ulano 925wr. We also sell Autosol emulsion, which is a good dual purpose emulsion, it can be used with both waterbased and solvent inks.

Location

Make sure you are doing all parts of the emulsion and exposure process in a light safe environment with NO outside or bright light. This includes mixing your emulsion, coating your screens, drying screens, exposure, and washout (as soon as screen is exposed as long as you wash it out straight away this is not a problem)..

A costing trough is the best way to get an even coverage of emulsion. Always check to make sure the coating trough has a straight edge and no damage otherwise you will get poor coverage and you can snag the mesh.

Here are a few things to watch out for if your images are not washing out correctly:
That you are not coating your emulsion too thick. One coat both sides should do it, with a nice even spread. There are sometimes where you may need some extra coats e.g. printing transfers and printing white onto a dark garment but you will need to adjust the exposure time.

Coating Your Screen

Coating Your Screen

That your film positive is very opaque and dark. If you hold it up to a light and can see through it, you need to double print your film to achieve a more opaque image.
That there is positive contact between your screen mesh and your positive film. If the film is not pressed completely against your mesh then you will get light reflection between your positive and your screen which will result in a blurry and not clear image. That’s why the glass is so important.
That you are exposing your screen for the correct amount of time, which will depend on the exposure system you are using. If you are unclear on exposure times please feel free to ask us. The simple run of thumb is – if the emulsions washes off too easily and you start to lose the stencil then the screen is underexposed and if after prolonged washing the stencil does not come through they you are likely to have overexposed the screen.
After you coat your screen, you want it to be COMPLETELY dry  before you expose the screen.

Exposing the image

Exposing Your Screen

Exposing Your Screen

To transfer your image onto your screen you will need to use an exposure unit. There are many different exposure unit set ups on the market and each has a different light source. Each having different light sources. UV, halide and halogen are very popular in the UK. Our Wicked exposure lamp has a 1000 watt halogen light source and is provided will all waterbased and Plastisol kits.

We also sell Actinic and Metal Halide exposure units which are able to expose quicker (typical exposure time is 2 minutes for an Actinic unit and 16 minutes for the lamp depending on size of the screen) than the cheaper lamp solution. Some units include built in drying cabinets making the whole process a lot faster.

A very large part of your decision if you are new to screen printing will be your budget and space. Exposure units vary dramatically in price. The WPS Lamp is small and compact,

After exposing and rinsing out your exposure, you want your screen to thoroughly dry (and ideally harden your screen, by exposing it to the sun or your exposure unit) before inking and printing. This process is often called double baking.

Before inking you need to use blocking tape (can use brown tape or professional blocking tape) to cover up areas on the screen not covered by the emulsion. Also fix any pinholes either using blocking tape or using screen filler which is a liquid emulsion, make sure you choose the right one as there are different versions for solvent and water resistant stencils.

Now you are ready to print

Registering Your Print

Registering Your Print

When you get bigger there are other options like the Revolutionary Riso QS200 Designed for the Professional Printer which prints directly from your computer onto a screen. Then the whole process takes under 5 minutes!

Or even let us do it for you with our exposure service.