How to Choose the Right Mesh Count for the Job

When looking at various mesh counts for screens, do you feel overwhelmed? How do you determine which mesh count to choose? They range from as low as 38 to as high as 400! There’s a reason for this diversity. Each mesh count serves a distinct purpose. Let’s explore the factors that determine the appropriate mesh count for achieving the best final appearance.

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First, what exactly is mesh count? Mesh count measures how many polyester threads interlace per square inch of the screen. For example, a 110 mesh screen consists of 110 threads per square inch. A higher mesh count signifies finer holes in the screen, while a lower mesh count indicates larger holes. With this in mind, let's assess when higher or lower mesh counts are necessary.

Print Detail

For high-detail prints, you need a higher mesh count (200 and above). Using a lower mesh count can cause lines or dots in the image to fall through the larger holes or be filled by the thicker thread diameter, resulting in a print that inaccurately represents your image - this leads to blurred lines and loss of detail. Conversely, designs with less detail should be printed through lower mesh counts (below 200) to achieve proper coverage. While higher mesh counts are feasible, they may require more time to reach the desired appearance.

Consider this print featuring small details, such as a snake. To capture that detail, a higher mesh screen is essential. This design was also printed on transfer paper, making the selection of mesh counts crucial for controlling the ink.

Now take a look at another print. It lacks fine detail, and the wording is fairly blocky. In this case, a lower mesh count is ideal for the job.

Ink Type

The thicker the ink, the lower the mesh count you'll want to employ. Heavy ink can easily pass through a lower mesh screen compared to a higher one. Let's discuss the differences when working with various ink types.

Water-Based vs. Plastisol Ink

Water-based ink is thinner than plastisol ink. Therefore, starting with high mesh counts for learning to print with water-based ink is best. This method allows enough ink to achieve a great print without over-application that might obscure the design. A standard mesh count for water-based ink typically ranges from 180-230. Once you gain confidence, you may successfully print on mesh counts as low as 156.

Related: How to Prepare a Screen for Water-Based Printing

Plastisol ink is generally thicker than water-based ink. Although instances arise requiring plastisol to be printed through a high mesh count (as previously mentioned), it can be effectively printed through lower mesh counts. A common standard for plastisol ink is a 156 mesh count, which permits enough ink to pass through for good coverage on garments.

Are you aiming for a super soft feel? Print plastisol through higher mesh counts. This process leads to thinner ink deposits. Consequently, less ink on the garment results in a softer texture. A screen with a mesh count between 200-305, combined with a hard squeegee, achieves this outcome.

Related: 5 Commonly Asked Questions About FN-INK Plastisol Ink

Metallic, Shimmer, & Glitter Inks

Specialty inks like metallic, shimmer, and glitter contain flakes that provide their shine. Metallic inks use the smallest flakes, so mesh counts can be as high as 230. Shimmer inks feature larger particles, making mesh counts between 86-110 the most effective.

Glitter inks contain the largest, most visible flakes. A mesh size of 36 is optimal for glitter inks, but you can also go up to a 64 mesh.

Print Surface/Substrate

The substrate you are printing on significantly influences the mesh count selection. For instance, printing on paper, like cardstock, requires using a high mesh count across various types of paper: posters, business cards, heat transfers, etc. Mesh counts above 200 are suitable for these jobs.

Why is this the case? When printing on paper, the ink has no absorption path. In contrast, when applying ink to a t-shirt, some ink soaks into the fabric, allowing for heavier deposits without compromising the design. On paper, especially with plastisol ink, the ink remains on the surface. A higher mesh count ensures sharper, crisper prints.

Printing Over an Underbase vs. Directly to Fabric

The ink type and garment material play critical roles in mesh count selection. Additionally, whether printing directly onto the fabric or over an underbase influences your choice.

Printing over an underbase resembles printing on paper due to its lack of porosity, causing the ink to merely rest atop the base without soaking in. Using a low mesh count can lead to excessive ink deposits causing bleeding or blurred designs. Thus, higher mesh counts and sturdier squeegees are required when printing over an underbase.

Printing directly onto fabric allows for more flexibility with mesh counts since some ink is absorbed. The specific choice depends on your target final effects.

When to Use Low or High Mesh Counts

When selecting the right mesh count for your project, many factors must be considered. Below is a checklist to guide you in choosing the suitable mesh.

Mesh Counts Below 156:

• Jobs lacking fine detail, such as block letters or simpler designs.
• Projects utilizing thicker inks, including white plastisol or shimmer inks with large flakes.

Image of blocky/simple design through low mesh.

Mesh Counts 156 & Above:

• Jobs with some detail, such as fine lines or standard halftones.
• Projects using water-based ink or printing over a white base.

Mesh Counts 230 & Above:

• SIM Process, high-resolution, high-detail printing, wet on wet printing.
• Jobs printed on paper, including posters and business cards.

Related: Mesh Count and You

Thin Thread vs. Standard Thread

Thin thread mesh is an excellent choice for printers striving for the highest quality prints with exceptional detail. Its thinner thread profile and wider dimensional openings facilitate ink flow across all types.

Employing thin thread mesh also boosts efficiency on both manual and automatic presses. Water-based ink clogs less frequently in thin thread mesh compared to standard thread, allowing for extended runs without compromising clarity and detail.

Nevertheless, it’s important to note that thin thread is more delicate and may not suit all shops. If that's the case, standard mesh remains an option.

Conversely, standard thread mesh has been a staple in print shops for many years. It is more resistant to popping and tearing during the printing process compared to thin thread mesh.

Contact us to discuss your requirements for mosquito screen mesh size. Our knowledgeable sales team can assist you in identifying the options best suited to your needs.

Regardless of the thread type selected for your shop, ensure it aligns with your workflow. If you're curious to explore different mesh types, feel free to do so! You might discover a new favorite.

Choosing the appropriate mesh count for your prints captures the essential details. Should you be uncertain about the right mesh to use, consider testing different options and conducting research to uncover what works best for your specific process. Before long, selecting the correct screen mesh for your projects will feel second nature.

Mesh count is a fundamental aspect for screen printers to grasp for achieving successful production results. It measures how many polyester threads intersect each square inch of a screen. Different mesh counts cater to various applications, and using an inappropriate mesh count can lead to errors in printed products.

To further clarify the importance of selecting the right mesh, we've compiled essential information on mesh counts.

Common Mesh Counts

Below is a breakdown of common mesh counts and their suitable inks and projects.

Low Mesh Counts

30 to 60 mesh is typically used for high-density and glitter inks, which require larger openings to allow large particles to pass through.

80 to 86 mesh serves well for metallic inks, athletic wear, and heavy inks. This mesh count is effective for high-opacity, heavy ink deposits, although using a thick underbase such as polyester is advisable to avoid ink bleeding.

Medium Mesh Counts

Mesh counts of 110 and 156 are versatile and indispensable, as they apply to various projects. They function as a good baseline for comparison since they accommodate everything from block letters to spot-color designs. They are ideal for higher-quality images due to their balanced ink deposit capabilities. Using an underbase is recommended for the 156 mesh, as typically, only one pass will suffice.

A 196 mesh count is perfect for achieving fine detail, neck tags, and preserving minimal ink deposits. This mesh helps prevent thin inks from bleeding since its small openings restrict ink flow.

High Mesh Counts

Mesh counts ranging from 200 to 230 cater to images requiring extreme detail and very thin inks, as tightly woven meshes prevent ink flooding on garments. Such counts can also provide plastisol inks with a softer impression on materials, though resulting images may possess lower opacity.

Mesh counts of 305 and above are typically reserved for the highest level detail required for photorealistic images and fine halftone dots. These counts suit graphic prints utilizing UV inks, with applications including signs, banners, and CDs. High mesh counts afford printers significant control over the ink deposited through the screen.

Why is Mesh Count Important?

Using the correct mesh count is vital for achieving optimal results in screen printing. Here are key factors to consider when selecting your mesh count.

Image detail plays a significant role. High-detail images necessitate higher mesh counts to maintain clarity, while low-mesh screens tend to allow ink bleeding, resulting in a poor image capture.

However, utilizing a high mesh count can restrict ink from reaching the substrate. This is especially true for thick inks, such as plastisol, which require lower mesh counts for effective transfer. Meanwhile, thin inks, like water-based varieties, prefer higher mesh counts to avoid flooding and bleeding.

The type of garment affects ink absorption as well. Different materials absorb ink differently; for instance, fleece absorbs more compared to less porous materials like paper, which would need a higher mesh count to facilitate proper printing.

Results of Using the Wrong Mesh Count

Here are a few likely outcomes of using an incorrect mesh count:

Blurred images are a common issue resulting from an unsuitable mesh count. An inappropriate screen can cause significant detail loss if it fails to distribute ink correctly.

Poor ink deposits also critically influence overall image quality. High mesh counts may prevent ink from passing through, while low counts lead to excessive ink, resulting in blown-out images.

Garments can also be ruined due to the above issues. While removal is sometimes possible, significant time loss often accompanies the process, highlighting the adage that time equals money.

Screens drying too quickly represent another production-related outcome due to improper mesh count selection. Higher mesh counts have a larger surface area, making them more susceptible to air exposure, which can extract moisture too quickly. This can lead to continuous rehydration of the ink and require frequent cleaning when working with water-based inks.

General Guide to Choosing Mesh Count

Mesh Count Use For 60-90 Thick plastisol inks 110 Printing with white plastisol inks
Do not use with water-based inks 160 Wide variety of ink types and substrates 200-230 Highly detailed artwork
Ideal for water-based inks on wood and paper 280-305 Finely detailed artwork
Halftones
CMYK process printing
Solvent and water-based inks

Improve Your Screen-Printing Production

There’s no singular correct mesh count for screen printing, and standardization among mesh count suppliers is minimal. The good news is you can often achieve comparable results with varying mesh counts; it merely requires some experimentation.

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