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Exposure, Washout and Stencil Results

Chapter 7

The Right Exposure Creates a Durable, High-Quality Stencil

Follow the correct process

Proper exposure and washout are critical steps in screen preparation. The right light source, exposure time and washout technique help you achieve clean details, strong stencils and consistent print results.

The exposure and washout process

Seven steps from pre-registration and film contact through exposure, washout, drying, inspection and press readiness.

1. Pre-Register

Mark registration targets on the screen to help align your film and artwork.

2. Image / Film Contact

Place the film positive in good contact with the emulsion. Use a vacuum frame for best results.

3. Expose

Expose using the recommended time for your emulsion, light source and coating thickness.

4. Wash Out

Use water to gently wash out the unexposed emulsion. Start with a soft spray, then increase pressure as needed.

5. Dry

Allow the screen to dry completely before handling or using on press.

6. Inspect

Check for clean edges, open details and any pinholes. Touch up if needed.

7. Press Ready

A properly exposed and washed out screen is ready for taping and mounting on the press.

Exposure results: finding the right balance

Comparison of underexposed, correctly exposed and overexposed stencil results, with detail close-ups and symptoms.

Underexposed

  • Emulsion washes out too easily
  • Edges look soft or rounded
  • Fine details may be lost
  • Stencil is weaker and may break down on press

Correctly Exposed

  • Clean, sharp edges
  • Good detail and definition
  • Strong and durable stencil
  • Resists breakdown on press
  • Provides consistent print results

Overexposed (Brittle)

  • Emulsion becomes too hard and brittle
  • Fine details may not fully wash out
  • Edges can appear thick or closed
  • Stencil may crack, especially during washout, taping or on press
  • Reduced ink transfer and shorter stencil life

Quick Fact

Exposure time depends on your emulsion type, light source, coating thickness, mesh count and artwork. Always run a step test to find the correct exposure time for your setup.

Pro Tips

  • Use a vacuum frame for best film contact.
  • Keep your exposure unit clean and maintained.
  • Maintain consistent coating thickness.
  • Use clean water and the proper spray pressure.
  • Let the screen dry completely before taping or printing.

← Previous chapter: Emulsion and Screen Preparation

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