Chapter 6
From a Clean Screen to a Quality Stencil
Proper screen preparation leads to better prints
A clean, properly prepared screen and the right emulsion are essential for a durable stencil, sharp image detail and consistent print results. Follow the correct steps and choose the emulsion type that best fits your production needs.
The screen preparation process
1. Clean & Degrease
Remove ink, emulsion and oils using a screen cleaner and degreaser.
2. Dry
Allow the screen to dry completely before coating.
3. Coat
Apply a uniform layer of emulsion using a scoop coater.
4. Dry Coated Screen
Dry in a clean, dark, dust-free area until completely dry.
5. Expose
Expose using the proper time for your emulsion, light source and artwork.
6. Wash Out
Wash out with water to remove unexposed emulsion and reveal the stencil.
7. Final Dry
Allow the screen to dry completely before printing.
8. Inspect
Check for pinholes, clean edges and overall stencil quality.
Types of emulsion
Diazo Emulsion
- Most common type
- Good all-around performance
- Mix with diazo sensitizer before use
- Limited shelf life after adding diazo
- Suitable for a wide range of inks and mesh counts
- Great for general purpose printing
Dual-Cure Emulsion
- Combines diazo and photopolymer technology
- Excellent durability and chemical resistance
- Limited shelf life after adding diazo
- Good for water-based, plastisol and specialty inks
- Ideal for high-volume production and longer print runs
SBQ / Pure Photopolymer
- No diazo required
- Ready to use
- Fast exposure times
- Excellent resolution and fine detail
- Ideal for high-detail and process printing
Capillary Film
- Pre-sensitized, dry film emulsion
- Consistent thickness and quality
- No mixing, coating or drying required
- Excellent for fine detail and multi-color printing
- Ideal for shops that want a clean, fast and repeatable process
Quick Fact
A clean, well-coated and properly exposed screen creates a durable stencil, which leads to sharper prints, fewer problems on press and a longer lasting screen.
Pro Tips
- Always work in a clean, dust-free environment.
- Follow the manufacturer’s instructions for your emulsion and light source.
- Keep coated screens out of direct light.
- Use the right emulsion for your ink and application.