The project was no small feat. We screen-printed a whopping 1,500 t-shirts, both front and back, in just 48 hours. The t-shirt design was jumbo, measuring 17″ wide by 23″ tall, covering a significant portion of the t-shirt.

The design was intricate, requiring a 6 color front and 6 color back screen setup. This complexity necessitated the use of halftones, Pantone matching, high detail, and simulated process screen printing.

Halftones, a technique that uses dots of varying sizes and spacing to create a gradient effect, were crucial for achieving the design’s subtle color transitions. Pantone matching was used to ensure color accuracy, vital for maintaining the integrity of the design and meeting the client’s expectations.

Simulated process screen printing, a technique typically used for reproducing photographic or full-color images, was employed to handle the design’s complexity. This method involves the use of color separation software and printing certain colors of opaque inks in a specific order on high mesh count screens.

The screen printing process began with the preparation of the screens. Given the design’s high detail, we used screens with a high mesh count to ensure the design’s intricate details were captured accurately. The screens were coated with emulsion, exposed, and washed out correctly, ensuring no pinholes or other exposed data. Our entire darkroom is fully automated which ensures quick turn arounds, repeatable processes, and accurate re-production on re-orders.

Once the screens were prepared, we moved on to the registration process. Each screen was aligned to the base screen using micro registration. This step is crucial for ensuring that all colors are printed on all garments in a consistent geometric plane, which is vital for maintaining the design’s consistency across all 1,500 t-shirts.

Throughout the process, we maintained open communication with the client. A sample before production photo was text messaged to the client to ensure the project was progressing as expected. This step was crucial for guaranteeing client satisfaction and ensuring that the final product met their expectations.

In conclusion, this jumbo screen printing project was a testament to our team’s technical prowess and efficiency. Despite the project’s complexity and tight deadline, we were able to deliver high-quality, consistent prints that met the client’s expectations. This project serves as a shining example of what can be achieved with technical expertise, efficient processes, and a commitment to quality in the screen printing industry.

So, next time you’re at the cinema and you see some cool movie merch, remember that jumbo screen printing by Garment Decor!