Fine-Tuning for Flawless Prints: The Art & Science of Squeegee Matching for Consistent White Ink Printing
My friend and mentor, Joe Clarke, would always preach, in screen printing, consistency is everything—especially when it comes to printing white ink. Too often, printers chase the “perfect white” by switching inks, when the real magic lies in the system behind the print: matching the squeegee blade to the proper mesh count, ink, and design.
In this article, we’ll break down a simple, repeatable system that ensures better results on every job, with an eye toward building what I’m calling the Ultimate White Printing Package. This article is dedicated to Joe and all he taught me and countless others.
The Foundation: Mesh and Squeegee Pairing
Choosing the right mesh count is step one. When you select the correct mesh for your design and ink type, you control ink volume, opacity, and print feel.
- Thin Thread Mesh (higher open area) is ideal for smooth white prints, especially with high-opacity inks.
- Standard Mesh offers durability but often at the cost of increased ink resistance and heavier hand feel.
Once mesh is selected, squeegee durometer (hardness) comes into play.
Choosing the Right Squeegee Durometer
Your squeegee is not just pushing ink—it’s controlling how much ink gets through and how it sits on the garment. Matching the durometer to the mesh, ink, and artwork is crucial for predictable results.
- 60 Durometer (Soft): For heavy ink deposits (not ideal for white on darks unless special effect is desired)
- 70 Durometer (Medium): Balanced ink deposit—great for general-purpose printing.
- 80–85 Durometer (Hard): Thinner ink layer, sharper detail, faster printing—perfect for white ink on darks with thin thread mesh.
Pro Tip: A harder durometer squeegee (80-85) allows for faster flood, faster print, and lays down a thinner, smoother deposit that cures better and reduces fibrillation.
The Role of RZ (Stencil Roughness) in White Ink Printing
A smoother stencil surface (low RZ value) is critical for top-tier white printing. A rough stencil slows down your print stroke, creates inconsistent ink shear, and forces ink down into the fibers of the shirt.
A smooth stencil (achieved with high-quality emulsion, proper coating technique, and exposure) allows:
- Faster printing speeds
- Ink to sit on top of the fibers, not soak in
- Brighter, cleaner whites
In short: smooth stencil + correct durometer = faster, better, longer-lasting white prints.
The Secret Weapon: Double Bevel Squeegee + Thin Thread Mesh
Want to unlock the best white you’ve ever printed? Combine a double bevel squeegee with thin thread mesh. Here’s why it works:
- The double bevel creates a sharper print edge and less drag, allowing smoother ink release.
- The thin thread mesh increases open area, letting your white ink flow effortlessly without flooding the garment.
- Pair with an 80 or 85 durometer for reduced ink deposit and lightning-fast print speed.
The result? Crisp, bright whites with reduced effort and greater consistency.
Coming Soon: The Ultimate White Printing Package
I’m currently building a complete Ultimate White Printing Package based on these principles—designed to take the guesswork out of white ink printing and help every shop achieve fast, consistent, eye-popping results. Stay tuned!
Remember: It’s not always the ink—it’s your system. Control the mesh. Control the blade. Control the stencil. And you’ll control the outcome.
If you’d like a consultation on dialing in your white ink setup or to get on the waiting list for the Ultimate White Printing Package, reply to this email or give me a call.
Next week we will take these lessons and expand them into printing spot colors and halftones.
