Why Screen Printing Still Matters

Why Screen Printing Still Matters

In a world dominated by fast digital printing, it might be tempting to think traditional methods are becoming obsolete. At Stewart Signs, the opposite is true. While the company operates an extensive range of high-quality, high-speed digital print technology, screen printing remains a valuable production technique, particularly when durability, precision and high-volume production are critical.

By combining both approaches, the Stewart Signs team can assess each project individually and recommend the most effective method, ensuring you always receive the right solution for your specific requirements.

While screen printing requires careful preparation and specialist expertise, the result is a print that is incredibly resilient, consistent and perfectly suited to demanding environments such as rail infrastructure, industrial labelling and large-scale commercial projects.

The Screenprint Process

Every screen printed job begins the same way, with digital design. Artwork is prepared and separated into individual colour layers, with each colour requiring its own dedicated screen.

This process ensures precise colour control and sharp detail, even when producing thousands of identical prints. For complex designs, multiple screens are used in sequence, with each colour carefully aligned to build the final image layer by layer.

Creating the Screen

The preparation of the screen is where the craftsmanship of screen printing really begins.

Each screen starts with a tightly stretched mesh frame that must be completely clean and evenly tensioned. Even small imperfections can affect the final result, so this stage demands attention to detail.

A light-sensitive emulsion is then applied to both sides of the screen in a controlled low-light environment. Once coated, the screen is left to dry in a dark, dust-free space.

The design is then transferred to the screen using a UV exposure process. Areas exposed to the light harden, while the unexposed emulsion remains soft. When the screen is washed with water, the soft emulsion rinses away, revealing the open mesh that will allow ink to pass through and create the printed design.

To ensure clean edges and prevent ink bleed, a blue filler is applied around the borders of the screen before printing begins.

Printing

With the screen prepared, the printing process can start.

Ink is placed onto the screen and pushed across the mesh using an industrial squeegee. The ink passes only through the open areas of the stencil, transferring the design directly onto the material beneath.

For multi-colour designs, the process is repeated for each colour using a different screen. Precise alignment ensures every layer sits perfectly with the others, producing a seamless final result.

Once printed, the ink must be cured through drying or heat treatment. This stage ensures the finished print is durable, long-lasting and resistant to wear.

Built for High-Volume Production

One of the reasons screen printing remains valuable is its efficiency at scale.

Although the initial setup requires time and expertise, once prepared the process is extremely efficient for producing large volumes of identical prints.

At Stewart Signs, screen printing is regularly used for:

• Rail industry signage and labelling
• Large-scale commercial print runs
• Compliance and H&S Labelling

Specialist Materials and Finishes

Another advantage of screen printing is its versatility across materials.

At Stewart Signs, print can be applied to a wide range of substrates, with material compatibility verified using relevant safety and technical data sheets. The inks used include the 3M 1900 Series and the Apollo GV Series.

Additional finishes can also be applied to enhance performance or appearance. These include:

• Photoluminescent laminates for visibility in low-light conditions
• Liquid laminates in matt or gloss finishes for added protection and durability

The Equipment Behind the Process

Behind every high-quality print is the machinery that makes it possible.

At Stewart Signs, two semi-automatic presses support screen printing production:

Unlike many modern print processes that operate on continuous rolls, screen printing at Stewart Signs typically works with sheet materials, with larger rolls cut down into manageable sizes before printing.

Precision Takes Time

Quality screen printing doesn’t end when the ink hits the material.

After printing, sheets are typically left to dry and outgas for at least 24 hours before further processing. This ensures any solvents fully evaporate and the print reaches its full durability before finishing stages.

A Craft That Still Delivers

Screen printing may be one of the more traditional print techniques in the industry, but its reliability and durability make it just as relevant today as it has ever been.

For Stewart Signs, it’s not just another printing method, it’s a core capability that enables the company to deliver robust, long-lasting signage for demanding environments.

State-of-the-Art Digital Printing Technology

In addition to traditional methods, Stewart Signs offers an extensive range of high-quality, fast digital print technology.

Contact us today to discuss your project and let our experts help you find the perfect printing solution for your needs.