Specialty Inks Selection and Application Workflow

Ink-Specific Separations: Generate separations optimized for discharge (which uses caustic chemicals), metallic (which needs density control), and fluorescent inks.

Garment Compatibility Check: Verify that your chosen ink works with your substrate—some discharge inks require 100% cotton; metallics need specific binder ratios.

Color Library Integration: Access ink manufacturer libraries (Rutland, Wilflex, Speedball) to preview colors before mixing.

Discharge Inks

• Removes fabric dye rather than adding ink on top
• Works only on 100% cotton or cotton-blend garments with reactive dyes
• Final color is fabric-dependent; white discharge on black cotton = light gray
• Softest hand (feel) of any ink type because no ink layer sits on surface
• Requires chemical discharge paste mixed with pigments; cannot use standard Pantone mixing formulas

Metallic Inks

• Contains aluminum or other metallic pigments for sheen and reflectivity
• Gold, silver, copper available; colors shift with light angle
• Requires lower mesh count (50–86 lines per inch) for proper ink flow
• Hand (feel) is thicker than standard plastisol; reduce flash cure or ink can flake
• Mix at correct ratio: too much pigment = dry printing; too little = no shine

Fluorescent Inks

• Reflects UV light for extreme brightness, visible even in low light
• Neon pink, neon yellow most common; less effective in other colors
• Fades faster than standard inks, especially outdoors (2–3 years typical)
• Requires higher mesh (110–156) for clean detail; lower mesh clogs easily
• Best used for novelty/event merchandise, not long-term wear

Glow-in-the-Dark Inks

• Phosphorescent pigment absorbs and re-emits visible light
• Glows brightest for 30–60 minutes after light source removed
• Fades with repeated charge cycles (typical life: 2–3 years)
• Requires exactly 3–4 layers of ink (transparency allows glow to emit)
• Cannot be mixed like standard plastisol; apply pre-made glow formulas only

Water-Based Inks

• Biodegradable, eco-friendly; softest hand of all inks
• Requires fast flash cure (may need 2–3 quick flashes between layers)
• Cannot layer well; best used as single-color prints
• Requires rapid production (ink dries in screens if idle > 15 minutes)
• Screen must drain completely; reclaiming is easier than with plastisol

1. Select Ink Type: Determine if discharge, metallic, fluorescent, or specialty ink fits design and garment.
2. Verify Garment: Discharge = 100% cotton only; metallics = any fabric; water-based = cotton/cotton-blend preferred.
3. Prepare Separation: Create separation suitable for chosen ink—heavier underbase for metallics, lighter for discharge.
4. Mix Ink: If using pigment-based ink (discharge, custom metallics), mix to correct ratio with binder. Pre-mixed inks (glow, fluorescent) use as-is.
5. Scoop and Flood: Apply ink to screen with flood bar. For metallics and glow, use 2–3 flood passes for uniform coverage.
6. Print First Layer: Lower squeegee pressure for metallics (flaking risk); normal pressure for discharge and water-based.
7. Flash Cure Between Layers: Water-based and glow require 20–30 second flashes between layers. Metallics may require flash between each pass.
8. Final Cure: After all layers, cure to manufacturer spec (typically 350°F for plastisol, 280°F for discharge, room-dry for water-based).

Discharge Inks: Cannot use standard Pantone formulas. Mix only with discharge paste and approved discharge pigments. Shelf life: 6 months in sealed containers.

Metallics: Mix plastisol base with metallic pigment at 10–20% by weight. Higher ratios = shinier but drier; lower = duller but smoother printing. Use within 6 months.

Water-Based: Never mix with plastisol. Store in sealed containers with minimal air space. Must reclaim screens same day or ink dries.

Metallic Ink Flaking: Over-cure or too much ink. Lower flash cure temperature and reduce squeegee pressure.

Discharge Not Removing Dye: Insufficient discharge paste, low curing temperature, or wrong fabric (discharge only works on reactive dyes). Increase chemical ratio and cure to 350°F+.

Water-Based Ink Drying in Screen: Idle time > 15 minutes. Flash spray and re-flood frequently. Reclaim immediately after production.

Glow Not Bright: Insufficient layers (need 3–4) or wrong ink formulation. Add extra layers and verify glow ink brand/spec.