Mesh count refers to the actual count of threads per square inch/cm (in both directions). It affects ink deposit, images, and print quality.

Typically, for spot design prints, you can use as low as 25 mesh up to 300 mesh count or more depending on the type of inks that you can use and the line thickness and font size that you use.

For halftone prints, it is dependent on the dot size (LPI) of your design. The lower the LPI, the lower the mesh count. The higher the LPI, the higher the mesh count. It is also dependent on the type of ink that you will use. Water-based inks, with proper printing technique, can work well up to the minimum of 150-180 mesh. Plastisol inks can work well up to 355 mesh.

Thread diameter refers to the actual diameter of fiber used to weave the fabric. It affects the thickness of ink deposits and strength of fabric.

Fine thread = superior print quality, due to less mesh interference

Fine thread = less durable, than heavier thread diameter.

The finer the mesh diameter, the bigger the mesh opening.

The finer the mesh count, the smaller the mesh opening.

For more ink deposit it is best to use lower mesh count and finer thread diameter.

For quality image, use higher mesh count, with finer thread diameter.

Monofilament Mesh:
Single strand, ideal for half-tone prints as it provides sharper image without the multi-thread interference. It is less prone to clog, ink trapping, and is easier to wash. Tension control is also achieved better.

Multifilament Mesh:
A multi-strand mesh that is more prone to clogging and requires frequent washing. It poses more problem with Organza type mesh.

Here is a typical application for mesh counts:

24 - 30 Mesh : Glitter inks

60 - 85 Mesh : Athletic printing (player numbers, etc.), heavy white under base prints, thick puff inks, metallic inks, cold peel and hot transfers

100 - 155 Mesh : General printing on white to dark substrates for average artwork details with no fine lines or halftones and as overprinting on underbase prints for darker substrates.

160 - 195 Mesh* : Multi-colored printing for semi-detailed artworks or larger halftones on light colored substrates or overprinting on an underbase print on darker substrates.

200 - 230 Mesh* : For detailed multi-color printing projects on light colored substrates or as an overprint on underbase prints for darker substrates.

305 - 355 Mesh* : For detailed artworks with fine halftones. Used for simulated process of for CMYK process.

* Higher mesh counts are suitable for plastisol inks and 230-305 mesh counts will usually produce a desired result.

Water-based inks will fall under general mesh counts, which is around 100-155 mesh.

1. It can support stencil/photo emulsion well.

2. It can provide edge definition, supports the artwork details.

3. It can control ink deposit or ink coverage, and color fidelity.

4. It regulates elasticity, off-contact, and provides an accurate artwork registration.

5. The thread of the mesh will least likely to run during heavy production runs.

YES, mesh color affects the stencil image quality as it reduces light scatter and aids in higher image quality. It produces a finer detail and halftone prints on finer mesh.

With staple wires, the blade of the staple can cut the mesh causing loose tension of the mesh. Using Frame Adhesives fastens the mesh surface area to the frame, secures it and protects the fiber from loosening up.

A low tension mesh can produce the following:

1. Increase the screen preparation time and artwork registration.

2. Cause high off-contact distance, producing less ink deposit, which will cause blemishes, streaks, non-uniformed coating, and pinholes.

3. Requires excessive squeegee pressure to allow more ink to penetrate to the substrate.

4. Ink flooding becomes difficult to achieve.

5. Wiping the substrate side of the screen happens more often in-between prints.

6. Highly prone to off-registration due to mesh movement, hence the prints will ten to splatter causing ink build-up and a slower production print.

7. The mesh deflects more on the center of the screen, which tends to make the applied stencil emulsion be thicker in the middle of the screen. This results in more exposure time in order to dry the thicker section of the stencil.

When stretching, do it slowly. Tension levels vary for every mesh count and thread type.

A screen tension level would depend on the mesh count and the thread diameter.

A lower mesh count would require a higher stretch tension.

Example:

110 mesh / 80 micron = 30 N/cm +/-

While a higher mesh count would require a lower stretch tension.

Example:

305 mesh / 35 micron = 16 N/cm +/-)

Expect to incur an average of 25% loss of tension in time with a higher tendency for higher mesh counts. Brand new screens are tighter at the beginning of the print run and can get worse at the end of the print run. Hence, a newer screen mesh will have better print quality and would gradually decline as more print runs are done. Frequent screen reclaiming will also reduce print quality.