Custom Screen Printing T-Shirts — Precision Bulk Factory
Screen printing remains the undisputed gold standard for bulk custom t-shirts, corporate uniforms, and fashion streetwear. At our Tirupur manufacturing plant, Polos Inc deploys multi-head automated carousel presses with calibrated squeegee pressure, non-phthalate plastisol, eco water-based inks, and high-density 3D puff effects for runs of 200 to 50,000+ pieces.
Non-Phthalate Plastisol Printing
The industry benchmark for opaque, vibrant colors on both light and dark cotton. Formulated without harmful phthalates or heavy metals. Produces sharp fine-detail edges, flexible stretch elasticity, and absolute color fidelity on cotton and blends.
Eco-Friendly Water-Based Inks
Water-based inks absorb directly into the yarn structure rather than resting on top. Yields an ultra-soft, breathable hand feel that you can barely detect by touch. Ideal for eco-conscious fashion brands, babywear, and lightweight summer apparel.
High-Density 3D Puff & Specialty
Add dramatic sculptural depth to your chest graphics with 3D high-density silicone or puff inks that expand under heat. We also engineer metallic gold/silver foil transfers, glow-in-the-dark phosphorescent inks, and caviar beads.
Screen Printing Mesh & Ink Chemistry Specifications
The precision of commercial screen printing relies on selecting the exact monofilament polyester mesh count and squeegee durometer for each ink formulation and graphic detail level.
| Mesh Count | Ink Compatibility | Deposit Thickness | Best Graphic Application | Durability Rating |
|---|---|---|---|---|
| 86 – 110 Mesh | High-Density 3D Puff, White Underbase, Glitters | Heavy / Thick Deposit | Bold block typography, heavy athletic numbers, puff badges | 50+ Industrial Washes |
| 160 – 200 Mesh | Standard Plastisol & Water-Based Spot Colors | Medium Balanced Deposit | Multi-color corporate crests, chest logos, vector line art | 50+ Industrial Washes |
| 230 – 305 Mesh | Fine Plastisol, CMYK Process, Simulated Process | Light / Soft Deposit | Photographic tonal gradients, micro-typography, half-tones | 40+ Commercial Washes |
| Discharge Mesh (156) | Water-Based Zinc Formaldehyde Agents | Zero Deposit (Dye Replacement) | Dark 100% cotton garments requiring breathable zero-hand feel | Lifetime of Garment |
Color Separation & Film Output
Our prepress engineers separate your artwork into discrete spot color channels, outputting high-density laser film positives with register marks.
Precision Stencil Exposure
Pneumatic mesh frames are coated with dual-cure emulsion and exposed under UV LED lights to achieve razor-sharp stencil lines down to 0.25 pt.
Automated Carousel Printing
Micro-registration heads calibrate color alignment across all print stations. Automated pneumatic squeegees ensure uniform ink shear on every garment.
Conveyor Tunnel Curing
Garments travel through our 12-meter forced hot-air tunnel dryers at 160°C (320°F), completely curing resin cross-links for maximum wash resistance.
Frequently Asked Questions — Screen Printing T-Shirts
Why is screen printing cheaper for large bulk t-shirt orders?
Screen printing requires upfront setup (screen creation and color separation), but once screens are calibrated on our automated carousel press, the cost per printed t-shirt drops dramatically. For runs of 500, 1,000, or 10,000+ pieces, it is significantly more cost-effective than DTG or digital transfers.
How many colors can you print on a single t-shirt?
Our automated carousel machines can print up to 12 spot colors per design simultaneously, complete with flash-cure units between stations to guarantee sharp boundaries and zero color bleed.
Can you screen print on polo shirts and hoodies?
Yes. We regularly screen print on honeycomb pique polo shirts, fleece hoodies, and zipper sweatshirts. We calibrate screen mesh and squeegee pressure specifically for textured pique knit surfaces to ensure crisp logo reproduction.
What artwork file formats do you accept for screen printing?
We recommend vector formats: Adobe Illustrator (.AI), Scalable Vector Graphics (.SVG), or high-res vector PDF with all text converted to outlines. If submitting raster files (PSD, TIFF, PNG), please provide minimum 300 DPI at 100% print scale.
Start Your Bulk Screen Printing Production
Speak directly with Sundar Thulasiraman and our Tirupur screen printing engineering team to review your artwork, ink options, and receive a competitive factory quote.