How to Get the Best Results from Screen Printing

Start With the Right Artwork

The single most important factor in a great screen print is your artwork file. Screen printing uses a stencil-based process where each color is burned onto a separate mesh screen. That means the file you send directly determines what gets printed — and bad files cannot be fixed without extra cost or delay.

Always submit artwork as a vector file. Vector formats like AI (Adobe Illustrator), EPS, or SVG are made from mathematical paths rather than pixels. They can be scaled to any size — from a chest-pocket logo to a full stadium banner — without ever losing sharpness. If you send a vector, your printer can work with it immediately.

Raster files like JPG, PNG, or low-resolution images downloaded from the internet are the number one cause of order delays. Even an image that looks sharp on a phone screen may be only 72 DPI, which will look blurry or pixelated when printed at shirt size. The minimum for raster artwork submitted for screen printing is 300 DPI at actual print size — ideally 600 DPI.

For more in-depth artwork education, Ryonet's screen printing blog is one of the best free resources in the industry, covering everything from color separations to exposure times.

Color Separations and Spot Colors

Screen printing works with spot colors — each color in your design is a separate screen and a separate ink. A three-color design needs three screens. This is why screen printing has setup costs (called "screen fees" or "setup fees") that are charged per color per design.

When preparing your artwork, use flat, solid colors rather than gradients or color blends. A gradient that fades from navy to gold looks beautiful in Canva but requires a technique called simulated process printing or halftone separations to reproduce on fabric — which adds complexity and cost. Simple, bold, solid-color designs print the cleanest and look the most professional on garments.

Stick to Pantone (PMS) colors when you need to match a specific brand color. Pantone is the universal language of print color. If you can give us the PMS number for your brand, we can mix the ink to match it precisely. Without a Pantone reference, colors can shift slightly between screens and monitors.

The PRINTING United Alliance is the largest printing industry trade organization in North America and publishes standards for color accuracy, equipment, and industry best practices.

Choosing the Right Garment

The garment you print on is just as important as the ink. Here is what to know:

• 100% ring-spun cotton is the gold standard for screen printing. Ring-spun cotton has a tighter, smoother surface than open-end (standard) cotton, which means ink sits more evenly and colors appear more vibrant.
• Garment weight affects durability and feel. A 5.3 oz shirt is a standard midweight tee. A 6.1 oz shirt is heavier and more durable — great for construction, outdoor events, or premium feel. Lightweight 4.3 oz shirts are popular for summer events but show ink bleed more easily.
• Avoid 100% polyester for plastisol ink unless your printer uses a polyester-safe ink formula. Polyester can cause dye migration — the shirt's dye bleeds up into the ink over time, turning white prints pinkish or yellowish.
• Dark vs light garments matter. Printing on dark shirts requires an underbase — a white ink layer printed first so colors stay vibrant. This adds one screen and increases cost slightly, but is essential for color accuracy on black, navy, or forest green shirts.

Plastisol vs Water-Based Inks

Plastisol ink is the industry standard. It sits on top of the fabric, produces vivid colors, is extremely durable, and requires no special wash care. It has a slightly raised, tactile feel when you run your finger over the print. Plastisol is the best choice for most bulk orders, team apparel, school spirit wear, and events.

Water-based ink soaks into the fibers of the garment rather than sitting on top. The result is a softer, vintage feel — prints feel like they are part of the shirt rather than on it. Water-based ink is ideal for fashion brands and retail-level apparel. It is less vibrant on dark garments and requires more careful washing. It also requires a heat-cured finish to prevent fading.

Impressions Magazine covers the decorated apparel industry in depth, including ink technology, garment trends, and business best practices for print shops and buyers alike.

Minimum Quantities and Why They Exist

Most screen printing shops have a minimum order quantity — commonly 12 to 24 pieces per design. This is because screen printing has a fixed setup cost: screens must be made, burned, and registered on the press for each job regardless of whether you order 12 shirts or 500. Spreading that setup cost over more units makes the per-shirt price drop significantly.

• 12–24 pieces: Minimum range, higher per-unit cost
• 48–72 pieces: Mid-tier, setup cost significantly diluted
• 144+ pieces: Bulk pricing, most cost-effective per shirt
• 300+ pieces: Wholesale pricing available

If you need fewer than 12 pieces or a single shirt, consider DTF transfers instead — DTF has no minimum and produces full-color results on any garment.

What NOT to Do

• Do not send a JPG or PNG you found online and expect it to print cleanly.
• Do not design with gradients, drop shadows, or glow effects unless you have discussed halftone printing with your shop.
• Do not use more than 6 colors unless you are prepared for significantly higher setup costs.
• Do not assume the color on your monitor will match the printed result exactly — always request a Pantone reference or a physical proof for brand-critical colors.
• Do not wait until the last minute. Standard turnaround for screen printing is 7–14 business days. Rush orders are possible but cost more.

"The best screen prints start with clean, simple, vector artwork. If your design looks great at 100% on a white background in Illustrator, it will look great on a shirt."

Ready to Print in Chicago?

At June's Tees & Things, we work with clients all over the Chicago area — from schools and community organizations to businesses and event planners. Our team will review your artwork before printing and flag any issues before they become problems. We offer free quotes and can advise on the best garment and ink combination for your project.

Visit our Chicago screen printing service page or call us at (773) 849-1854 to get started.