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Simulated Process Printing

Photorealistic Prints with Vintage Soul

Max Size: 17" x 23"50 Piece Minimum
Starting at $3.35/piece
See full pricing →

Simulated process screen printing reproduces full-color images—especially photorealistic artwork—using traditional screen printing techniques. By separating your design into a custom set of spot colors with halftones, we create stunning prints that pop on any shirt, especially dark ones. It's our go-to for anything complex, vivid, or requiring that nostalgic concert tee feel.

And you will get

Factory Direct Pricing
50 Piece Minimum Order
Two-Week Turnaround
Rush Upgrade Available
Hundreds of 5-Star Reviews
Located Near Los Angeles
The Latest Technology
Professional Account Reps

How Does Simulated Process Work?

Simulated process printing works by separating a full-color image into a custom set of spot colors. These colors are carefully chosen to reproduce gradients, shadows, highlights, and photorealistic details through halftones and layering techniques. Unlike digital printing (CMYK), simulated process uses Pantone-matched spot colors that can be more vibrant and precise. The end result is a soft-feel, photorealistic print with that iconic band tee quality.

1

Color Separation

Your artwork is analyzed and separated into individual spot colors optimized for screen printing.

2

Halftone Generation

Gradients and tones are converted to halftone patterns for smooth transitions.

3

Screen Creation

A separate screen is created for each color in the separation.

4

Print Sequence

Colors are printed in precise sequence, building up the image layer by layer.

5

Final Cure

The completed print is cured to bond all layers permanently to the fabric.

Simulated process print on LA Apparel 1801GD

Photo-Realistic, Factory-Direct

Complex designs printed with precision. Connect with a dedicated rep.

Free Consultation

No obligation — just honest advice on your project

Your Dedicated Rep

Work 1-on-1 with an expert who learns your brand

Prefer to Talk?

Call us at (855) 942-7636

✓ No obligation✓ Free consultation✓ Dedicated rep
Built for Artists

Why Touring Artists Love Simulated Process

Simulated process screen printing is the go-to for artists who want merch that looks as good as the album cover.

From photorealistic portraits to moody gradients, this method brings complex art to life—especially on dark tees. It's built for tours, built for fans, built to last.

  • Reproduce album art with stunning accuracy
  • Vibrant colors that pop on black shirts
  • Durable prints that survive the mosh pit
  • That classic, vintage band tee aesthetic
Simulated process back print on LA Apparel

Simulated Process vs Digital Screen Printing

Choose the right method for your artwork

FeaturesSimulated ProcessDigital Screen Printing
DefinitionHalftones + spot colors for photorealistic printsDigital print head for full CMYK color
Best ForVibrant colors, vintage feel, Pantone matchingPhotorealistic with complex color gradients
Color AccuracyPantone match any colorCMYK only, reduced vibrancy
DetailArtistically interpretedTrue-to-image
Max Print Size17" x 23"15" x 18"
Special Effects✓ Yes✗ No

Why Choose Simulated Process?

For artwork that demands the best

Pantone Color Matching

Unlike digital methods, simulated process allows exact Pantone matching for brand-accurate colors.

Photorealistic Results

Reproduce portraits, album art, and complex imagery with stunning detail and depth.

The Vintage Concert Tee Feel

That iconic, nostalgic look of classic band merch—soft ink, rich colors, timeless appeal.

17" x 23" Max Size

Larger than digital screen printing, giving you more canvas for impactful designs.

Special Effects Available

Combine with puff, metallic, or high-density inks for added dimension.

Soft Hand Feel

Carefully controlled ink deposit creates a comfortable, wearable print.

Simulated Process Printing FAQ

Common questions about our simulated process printing services

The minimum order quantity for custom simulated process printing is 50 pieces.
Simulated process printing prices are custom quoted per project. Pricing depends on several factors, including: • Garment type (e.g., t-shirts, sweatshirts, performance wear) • Number of print colors and print placements • Order quantity (larger simulated process printing orders receive volume discounts)
Our standard simulated process printing production turnaround time is 10 business days from the date of final artwork approval and receipt of all blank garments. Turnaround time may vary depending on: • Current production volume • Order size and print complexity • Add-on services (relabeling, folding, bagging, etc.) • Shipping or delivery requirements
Absolutely. If you're undecided on which garment to use for your simulated process printing project, we strongly recommend ordering blank samples before proceeding with a full production run. This helps ensure you're confident in your garment selection before printing begins.
Yes. We offer tiered pricing for bulk simulated process printing orders, meaning the more you order, the lower the cost per piece. Our minimum order is 50 pieces, with price breaks available at 75, 100, 150, 250, 500, and 1000 pieces.
Yes, we can re-label blank garments, but it's important to understand the type of label currently on the product to determine the best approach for rebranding. Tear-Away Labels If your shirts come with tear-away tags, we will remove them free of charge and print your custom neck label in its place. Cut-Away Labels Some garments may come with cut-away labels, which are designed to be removed by cutting. While we can remove these as well, it requires additional labor and may incur additional charges.
Yes. Rush simulated process printing orders are typically completed within 2–4 business days, depending on the scope of the project and our current production capacity. Rush turnaround is contingent on the following: • Artwork approval and blank garment delivery must be finalized upfront • All order details (sizes, styles, and print specifications) must be confirmed with no revisions • Availability of your requested garments from our suppliers Rush fees apply and are quoted based on order complexity, decoration method, and required ship or pickup date. Please contact your sales representative as early as possible to confirm if a rush production slot is available. Rush jobs are scheduled on a first-come, first-served basis.

Simulated Process Portfolio

Photorealistic prints with character

Expert Advice

5 Tips for Simulated Process Printing

1

Be Flexible

Simulated process may require color adjustments. Trust your rep—minor tweaks often improve the final result.

2

Optimize Color Count

We balance design integrity with cost by reducing colors where possible. More colors = higher cost.

3

Leverage the Garment

Consider how the shirt color can replace ink colors in your design, creating a more cost-effective print.

4

Mind Ink Density

Lighter ink coverage gives a softer, more premium feel. We optimize for comfort and quality.

5

Expect Adjustments

Minor tweaks during setup are normal. Simulated process is an art as much as a science.

Need it faster? Rush turnaround available — as soon as 48 hours.

Ready for Photorealistic Prints?

Get a quote within 24 hours. 50 piece minimum.