Achieving a Softer Feel in Screen Printing: A Step-by-Step Guide to Thin Ink Deposits

Published 25 days ago • 3 min read

Achieving a Softer Feel in Screen Printing: A Step-by-Step Guide to Thin Ink Deposits

Screen printing is as much an art as it is a science, especially when aiming for a premium, soft-hand finish. Thick, plasticky prints are a relic of the past—today’s customers demand lightweight, breathable designs that feel as good as they look. By combining precise mesh selection, optimized coating methods, specialized inks, and strategic press settings, you can consistently produce prints with a softer hand and thinner ink deposit. Here’s how to master the process.

Why Softness Matters

Thick ink deposits can leave prints stiff and uncomfortable, particularly on delicate fabrics like tri-blends or performance wear. A thinner ink layer not only improves comfort but also enhances durability (less cracking) and reduces production costs (less ink used). Let’s break down the key components of this method.

The 5-Step Process for a Softer Print

1. Choose a Thin Thread, High Mesh Count, High Tension

  • Ideal Mesh: Use 230-305 thread count screens.
    • Higher mesh allows less ink to pass through, creating a thinner deposit.
    • Thin thread mesh (e.g., 305) offers finer detail and smoother ink flow.
  • Avoid Lower Mesh: Lower counts (110-160) deposit more ink, leading to a heavier hand feel.
  • Check Your Tension!: The most critical tool you can have is a tension meter. Check your screens….and check them often.
  • *I preferred a 180/45 or 198/45 for a base.

2. Apply a 1/1 Coating Method

  • What is 1/1? Coat the screen once on the substrate side and once on the squeegee side.
  • Why It Works: Thinner emulsion layers prevent excess ink from pooling in the stencil.
    • For comparison: A 2/2 coating on lower mesh traps more ink, while 1/1 on high mesh ensures minimal buildup.

3. Use an 80-85 Durometer Squeegee

  • Harder Squeegee Benefits:
    • Less Pressure: A harder blade (80-85D) requires less force, reducing ink penetration.
    • Smoother Pass: Glides evenly over the mesh, preventing “pushing” excess ink through.
  • Pair with Sharp Edges: Maintain a sharp squeegee edge for clean ink release. I cannot stress this enough.

4. Incorporate Rutland Chino Base

  • What is Chino Base? A low-bleed, soft-hand ink base designed for lightweight deposits. Can use to simulate HSA feel, matte your ink or tint for tone on tone prints.
  • How to Use It:
    • Mix Chino Base with plastisol inks (e.g., 20-30% ratio) to improve fluidity.
    • Enhances ink flow without sacrificing opacity, critical for high mesh screens.
  • Result: Ink becomes more fluid, allowing it to pass smoothly through fine mesh.

5. Optimize Press Settings for Fluid Ink

  • Flood Bar Speed: Run the flood bar fast to thinly distribute ink without overloading the screen. 7-8 on most presses.
  • Squeegee Speed: Increase squeegee speed to 5-7 (on most presses) for a quick, clean pass.
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Why This Process Works

  • Thinner Mesh + 1/1 Coating: Limits ink volume, reducing deposit thickness.
  • Hard Squeegee: Minimizes pressure, preventing ink from being forced into the fabric.
  • Chino Base: Lowers ink viscosity, ensuring smooth transfer through high mesh.
  • Fast Flood/Squeegee: Prevents ink from sitting too long on the screen, which can lead to clogs or uneven deposits.

Efficiency Gains: Eliminate Guesswork

This method isn’t just about quality—it’s about repeatability. By standardizing your approach:

  1. Fewer Errors: Consistent settings reduce misprints and ink waste.
  2. Faster Training: New hires follow a clear, proven process.
  3. Quick Turnarounds: No time wasted adjusting variables mid-run.

Example: A hoodie print that previously required trial-and-error adjustments now runs smoothly with pre-set mesh, coating, and press settings.

When to Skip the Underbase

For ultra-soft prints on light garments, consider skipping the underbase and using a high-opacity ink mixed with Chino Base. This eliminates an entire screen and flashing step, further speeding production.

Final Thoughts

A softer print isn’t just a luxury—it’s a competitive edge. By integrating high mesh counts, precise coatings, specialized inks, and optimized press settings, your shop can deliver premium-quality prints efficiently and consistently.

Pro Tip: Test this method on sample garments first. Adjust squeegee angles or ink ratios slightly to match your specific equipment and fabric types.

Embrace the process, and watch your prints—and customer satisfaction—rise to new heights!

Key Takeaways

  • High mesh (280-305) + 1/1 coating = thinner ink deposit.
  • 80-85D squeegee + Chino Base = smooth, soft prints.
  • Fast flood/squeegee speeds = efficient, consistent results.
  • Standardizing steps = fewer errors, faster production.

​Rutland Chino Base for Screen Printing | Texsource — Texsource Screen Printing Supply​

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