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Screen Printing
Screen printing is a printing technique that uses a mesh screen, ink, and a squeegee. It sounds simple, right? Not so fast, there is a wide variety of inks, many different fabrics, and even environmental issues that must be taken into consideration when creating your perfect shirt. We have been perfecting our craft for 45 years, which allows us to create vibrant, long-lasting prints with exceptional detail and durability. We know good quality work never goes out of style.
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Frequently Asked Questions
What is the minimum order quantity for custom screen printing services?
The minimum order quantity for custom screen printing at T-Shirt Engineers is 12 pieces. This is the point at which the per-screen setup cost, creating a separate mesh screen for each colour in your design, becomes cost-effective on a per-garment basis. For orders under 12 pieces, we recommend DTF (Direct to Film), heat transfer, or direct-to-garment printing, all of which we offer in-house and which deliver excellent results at smaller quantities. If you are ordering for a team, event, or business, 12 pieces is a straightforward threshold, and bulk pricing improves significantly at 24, 48, and 72 pieces. Call us at 308-382-8742 if you are unsure which method fits your order size and budget.
How many colors can be included in a single screen-printed design?
T-Shirt Engineers can screen print designs with up to 8 spot colours in a single print location, which covers the vast majority of logos and artwork. Each colour requires its own separate mesh screen, so colour count directly affects setup cost. A 1-colour print is the most economical, and each additional colour adds a screen charge. Most corporate logos and team designs use 1 to 4 colours, which is the sweet spot for balancing visual impact with cost efficiency. For designs requiring photographic detail or gradients with more than 8 colours, we can use simulated process printing, which recreates complex images using a limited number of overlapping spot colours. Our design team will review your artwork and recommend the most cost-effective colour approach before production begins.
What types of ink do you use, and will the print crack or fade over time?
T-Shirt Engineers primarily uses plastisol ink for standard screen printing, the industry’s most durable and colour-accurate ink type, which sits on top of the fabric and delivers vivid, wash-resistant results that hold up for the lifetime of the garment. For soft-hand applications and lighter garments, we use water-based inks, which absorb into the fabric fibres and produce a softer feel. For specialty finishes, we also work with discharge inks, metallic inks, and high-density inks, depending on your design and fabric requirements. All prints are cured in a commercial-grade heat tunnel at the precise temperature and speed required to permanently bond the ink, a process we have refined over 44 years of production. When printed and cured correctly on the right fabric, a screen-printed design will not crack, peel, or significantly fade for the normal lifespan of the garment.
Are there specific file formats required for artwork to be screen-printed?
The preferred file formats for screen printing artwork are vector files, specifically: AI (Adobe Illustrator), EPS, or PDF. Vector files are resolution-independent, meaning they remain perfectly sharp at any print size without pixelation. High-resolution raster files, such as .PNG or .JPG, can sometimes be used if the file is at least 300 DPI at the intended print size, but they are not always suitable for every design. If you only have a low-resolution logo, such as one saved from a website or a small JPEG, our in-house design team can redraw and digitize your artwork into a clean, production-ready vector file at no extra charge for standard logos. Providing the right file format upfront is the single biggest factor in ensuring your print looks exactly as intended.
How is the cost of a screen printing project calculated?
Screen printing costs at T-Shirt Engineers are calculated using four main variables: the number of garments ordered, the number of colours in your design, the number of print locations (front, back, sleeve), and the garment itself. Setup involves creating a separate screen for each colour, typically a one-time screen charge per colour per location, which is spread across your total quantity. This is why larger orders have a significantly lower cost per piece: a 12-shirt order carries the full screen setup cost across fewer garments, while a 72-shirt order spreads that same cost much more efficiently. As a general guide, a single-colour print on a standard t-shirt starts from approximately $8 to $12 per piece at 12 units and drops considerably at higher quantities. For a detailed breakdown of pricing by order size and colour count, visit our screen printing cost guide at https://tshirteng.net/blog/how-much-does-screen-printing-cost/, or call 308-382-8742 for a quote specific to your project.
How long does screen printing take?
Standard turnaround for custom screen printing at T-Shirt Engineers is 7 to 14 business days from the date your artwork is approved, and your order is confirmed. The most common reason orders take longer than expected is artwork. If your file needs to be redrawn, converted, or revised, that adds time before production can begin. Providing a production-ready vector file upfront is the fastest way to move your order through. Rush turnaround is available for urgent orders if you have a specific event date or deadline. Tell us when you place your order, and we will do everything possible to meet it. Call 308-382-8742 to discuss timing before you place your order if a deadline is critical.
What is the difference between screen printing and digital printing?
Screen printing and digital printing are two different processes suited to different order types. Screen printing creates a physical stencil for each colour, and forces ink through it onto the garment, producing prints that are extremely durable, highly opaque, and cost-effective at quantities of 12 or more. Digital printing, including direct-to-garment (DTG) and DTF (Direct to Film), prints artwork directly onto the fabric like a high-quality inkjet printer, with no screen setup and no minimum quantity. Screen printing is the better choice for bold, colourful logos on medium to large orders where you want maximum colour vibrancy and longevity. Digital printing is better for photographic designs, very small runs, or one-off pieces where setting up physical screens would not be cost-effective. T-Shirt Engineers offers both methods in-house. Call us at 308-382-8742, and we will recommend the right process for your specific design, quantity, and budget.
Can you screen print on any colour shirt?
Yes, T-Shirt Engineers screen prints on garments of any colour, including black, navy, charcoal, and other dark fabrics. The key difference with dark garments is that most designs require an underbase layer, a white or light-coloured ink printed first, before the design colours go on top. This ensures your colours appear vibrant and accurate rather than washed out by the dark fabric underneath. The underbase counts as an additional screen and adds a small cost, but it is essential for a professional result on dark shirts. On white and light-coloured garments, no underbase is needed, and the ink prints directly. Our team will identify whether your design requires an underbase when we review your artwork, and we will always advise you before production begins.
Is screen printing good for small businesses?
Screen printing is one of the most cost-effective branding tools available to small businesses, and it is a core part of what T-Shirt Engineers does for Nebraska businesses every day. Branded staff uniforms, promotional t-shirts, event apparel, and workwear all benefit from screen printing’s durability and low per-unit cost at moderate quantities. For a small business ordering 24 to 48 shirts at a time, screen printing consistently delivers a better-looking, longer-lasting result than digital alternatives at a comparable or lower cost per piece. The minimum order of 12 pieces makes it accessible even for very small teams. Beyond apparel, we also produce signage, vehicle graphics, and promotional products under the same roof, which means small businesses can handle their entire branding needs through a single local supplier. Call 308-382-8742 to discuss what screen printing can do for your business.
Do you screen print on items other than t-shirts?
Yes, T-Shirt Engineers screen prints on a wide range of garments and items beyond t-shirts. We regularly print on hoodies and sweatshirts, polo shirts, long-sleeve tees, performance and moisture-wicking shirts, tank tops, tote bags and canvas bags, aprons, and workwear, including hi-vis and heavy-duty shirts. We also print on non-apparel items such as promotional products where the surface is compatible with screen printing ink and the curing process. For items that are not suitable for traditional screen printing, such as caps, structured outerwear, and bags with complex surfaces, we use embroidery, heat transfer, or direct-to-film printing to achieve the same branded result. If you have a specific item in mind and are not sure whether screen printing is the right method, bring it in or call us at 308-382-8742, and we will advise you on the best approach.