Printing Techniques
Modern printing techniques are numerous, and the factors to consider are closely tied to each individual customization project, whether it involves electronic gadgets, promotional items, or technical apparel. Our creative and technical team will guide you in bringing your idea to life from the very first design phase, helping you choose the ideal printing technique for your purpose.
There are multiple factors to consider, but the material on which the printing will occur is probably the first determining factor. Not all techniques are suitable for all fabrics; we might use screen printing or direct digital printing for customized cotton t-shirts, while sublimation guarantees optimal results on synthetic materials.
Another important factor is the quantity of customized items you intend to produce, which significantly affects the price per unit, as larger print runs allow for better amortization of any setup costs.
Also to be considered are the number of colors and the complexity of the design, as well as the printing position and the size of the graphic: these are all elements to weigh in order to achieve the perfect mix for a good quality-to-price ratio.
Screen printing is one of the oldest printing techniques yet remains one of the most widely used in the modern world. It is used to reproduce images on virtually any material.
Printing occurs by means of a screen on which a special mesh fabric is stretched. To simplify the process, we can say that the screen, also called the printing frame, acts as a frame and the image to be transferred is impressed onto the fabric. In the case of multi-color prints, the process is repeated for each shade.
.This technique allows us to print subjects of any size and various shapes on any material. It can be used for printing on any fabric, thanks to its excellent resistance to frequent washing, although the best results are always achieved on 100% cotton.
Screen printing can be used on plastic, wood, cork, labels or decals, and also on paper and PVC for decorating glass, tiles, or ceramics.
It is one of the most economical printing techniques but, since it requires setup costs, a minimum quantity of 100 pieces is recommended to amortize the costs. The screens produced remain available for any subsequent reprints, which helps to reduce the unit price.
Direct digital printing is the most suitable technique for prints requiring very high quality, such as images and complex designs with many gradations and fine details. Unlike screen printing, direct digital printing is not subject to setup costs and therefore proves more cost-effective for small quantity prints.
The printing process uses multiple printheads with different colors that, moving across the garment to be printed, deposit the dye onto the fabric or material to be printed. A heat press then fixes the color onto the product to be printed.
In addition to the very high quality of details, this printing technique guarantees excellent durability over time and a very soft result on fabrics because the colors do not simply adhere but penetrate inside, coloring the fibers. It allows for remarkable quality on both 100% cotton and cotton blends, but can also be used on non-textile materials such as PVC, photographic or adhesive paper, polycarbonate, plexiglass, and wood.
For large quantity orders, direct digital printing is replaced by polychrome printing which lowers costs and improves cost-effectiveness.
Transfer printing is based on the heat application of specific plastic films onto fabric. It has no setup costs and allows the use of both Pantone color films and “white” films which are first digitally printed and then heat-applied.
Transfer printing is one of the most versatile and economical printing techniques; however, it is the one that appears least natural, due to the glossy effect transferred from the adhesive used.
This technique allows for single-color or four-color prints with similar costs, and can be used on any fabric, while it is not recommended for non-textile materials where sublimation printing is preferable.
Transfer printing is ideal for printing solid shapes such as large lettering, logos, or images. For jagged edges or very detailed graphics, however, since it is necessary to simplify the transfer outline, the result is a transparent glossy profile that may not be appealing.
Sublimation printing on objects is the evolution of heat transfer but without support transfer. Color fixation occurs through heat and pressure from a specific paper to synthetic fabric. In this way, the graphic image passes through the polyester fibers and fixes permanently.
It is particularly used in the sportswear sector, for flags and pennants, and for swimwear precisely because it requires synthetic fabrics pre-treated with polyester or nylon. Beyond textiles, its use is particularly suitable for all types of customized gadgets, as it allows for very attractive decoration thanks to the brilliant color rendering, solid blacks, and the level of detail that can be achieved.
Sublimation inks have excellent resistance over time, to abrasion, to sunlight, and to frequent washing. The printed design does not break or wear over time because it is bonded to the fabric fibers. The most frequent use is related to sportswear used in soccer, cycling, and swimming since this technique does not alter the breathability, elasticity, and resistance of garments.
Sublimation printing allows for four-color printing or solid colors and has no color limitations. As with digital printing, it does not involve the fixed setup costs typical of screen printing, ensuring a good price even for limited runs.
Embroidery, widely used for customizing sweatshirts or polo shirts, is also widely used as a decorative technique for t-shirts. Threads of different colors are used to reproduce logos or images in the desired shape and position. It is optimal for small logos and graphics, especially in the front position on the heart side or on the sleeve.
Although it can also be done in large sizes, for example on the back of the shirt, it is not recommended as the garment would become very heavy.
Embroidery has a setup cost that is related to machine configuration. The larger and more complex the embroidery, the higher the initial cost. This technique can be used on any fabric, but the best results are obtained on fabrics with a fairly high specific weight, usually cotton.