Screen printing is a versatile and inexpensive way to print using off-the-shelf silk stencils. If your client wants to get a universal design, or you just want to give free rein to your creativity, you can try to make a stencil for silk-screening yourself. While you may need specialized tools such as a vinyl cutter or silkscreen emulsion to make a stencil, you can also cut a stencil by hand as well. With sufficient practical experience, both beginners and quite professional craftsmen can easily make stencils from suitable materials.
Steps
Method 1 of 3: Making a stencil by hand
Step 1. Draw or transfer the outline of the design onto mylar film or vinyl
After choosing a suitable design, transfer the corresponding image to the selected material for making a template. Use a fine-tip marker to help you see your pattern. Secure the film or vinyl with masking tape to more accurately outline the contours of the design.
- If you need to draw straight lines, use a metal ruler.
- If you make a mistake on mylar or vinyl, use rubbing alcohol and a soft cloth to wipe off the stain.
Step 2. Attach the mylar film or vinyl to a hard, clear plastic (such as acetate)
This is a necessary preparatory step for cutting out the template. Again, use masking tape to secure the design in place. Position the mylar or vinyl so that the plastic protrudes at least 2.5 cm beyond the edges of the design.
Step 3. Cut out the stencil with a sharp knife
Similar to using a vinyl cutter, making a stencil by hand requires precise cutting. Use a sharp utility knife to remove any areas of the mylar film or vinyl that should not interfere with the design. Be very careful when creating complex designs so that you don't accidentally delete the wrong parts of the design.
- In the areas you remove, the ink will come into contact with the fabric when the design is printed. Keep this in mind when you cut the stencil.
- Rotate the stencil when you cut it to make it easier to work with.
Step 4. Attach the stencil to the screen for silk screening
Apply transfer film evenly to the back of the stencil. When ready, remove the film backing and glue the stencil as evenly as possible onto the silk screen printing screen. The stencil should be applied to the back of the silk screen so that the pattern is not damaged as it passes through the printing press.
Method 2 of 3: Using a vinyl cutter
Step 1. Buy or rent a vinyl cutter
This device is capable of transferring to vinyl and cutting precise patterns for intricate stencils. If you don't have your own plotter, you can try to rent it temporarily from a craft store for a fee.
Step 2. Create a high contrast image on your computer
Create your designs online using an image editing program (such as Photoshop or Inkscape). Refer to the user's manual that came with your plotter to check the programs that are compatible with it. The graphics should be simple enough to easily transfer onto fabric. Once you're done with your design, convert it to a format that your vinyl cutter can handle.
Most vinyl cutters prefer file formats such as "SVG" or "PDF."
Step 3. Load the plotter with vinyl
Slide the end of the roll into the machine so that it hangs over the other side. The vinyl should sit on the main roller, but under the locking rollers.
The color of the vinyl you use doesn't matter as it won't transfer onto the fabric itself during silk screen printing
Step 4. Load the file into the vinyl cutter
When you export your file to a plotter, the stencil template will be ready to print. The plotter will trace the contours of the drawing with his knife and create a vinyl stencil for you. Depending on the complexity of the design, the entire process can take from a few minutes to an hour.
The plotter will cut through the outlines of your drawing, but not completely. Then you will have to cut out all the extra areas with a knife yourself
Step 5. Trim off the excess vinyl stencil
Use a sharp knife or other special tool to remove excess vinyl. The thickness of the knife used depends on the complexity of the stencil: the more complex the pattern, the thinner the knife required for this.
Remember that you are making a "negative" of your design. Screen press ink will be printed where areas of the vinyl are missing
Step 6. Create a vinyl frame for your silk screen
Cut a piece of vinyl to the size of your silkscreen screen, which will become the stencil frame. Use a sharp knife to cut a rectangle large enough from the middle to fit your stencil. Place the prepared frame on the mesh screen and secure with masking tape.
- Arrange the materials in the following order: mesh screen at the bottom, center bezel, and stencil at the top.
- Make sure the stencil image fits completely into the rectangular opening of the frame before removing the liner from the transfer ribbon.
Step 7. Use transfer film to secure the stencil
Stick the transfer tape as evenly as possible to the back of the stencil. When you are ready to transfer the stencil to the screen for silkscreening, remove the liner from the transfer film and secure the stencil in the previously cut rectangular slot. Smooth the stencil with firm hand movements so that there are no air bubbles under it.
Method 3 of 3: Apply a Photo Emulsion for Silk Screen Printing
Step 1. Cover the silk screen with photo emulsion
A photographic emulsion is a gel-like substance that is sensitive to light. When applied to fabrics such as silk, it is able to perceive images from photographic paper and thus create stencils. Apply a thin layer of emulsion to both sides of the screen, leaving about 2.5 cm around the border.
Cover the screen for silkscreening with emulsion in a room with a minimum amount of light (or in a completely dark room). If you have a special light-tight box, you should have it at hand when applying the emulsion
Step 2. Place the screen in a dark room or light tight box
After covering the screen with gel, let it dry in the absence of light. Immediately place it in a dark room or lightproof box where UV light cannot touch the screen. The drying process will take 3-5 days, depending on the size of the silk screen.
- Do not take the screen out of the dark earlier than 2-3 days, as access of light to the wet gel will ruin it. Refer to the instructions on the package with the photographic emulsion for the exact drying time.
- Silkscreen screens dry faster in the summer than in the fall because the emulsion gel reacts better to heat.
Step 3. Print your stencil design on transparencies
After the screen has dried, it is necessary to print the design of the future stencil on a transparent film for printing. Most printers are compatible with transparencies, but you may need to adjust the printer settings accordingly. Check your printer's user manual for specific instructions.
- Handle transparencies by the edges to avoid smudging the design.
- Allow each sheet to dry for five minutes before stacking or touching the design.
Step 4. Attach the design to the silk screen
Attach the stencil template to the bottom of the screen. Press it down with a piece of transparent glass or other heavy non-combustible transparent object that will securely fix the template for the period of image transfer.
Step 5. Place the screen on a matte black object
This will ensure an even exposure when the screen is placed under the UV lamp. Ideally, use a chalk board if you have one, or spray black spray paint on a rectangular piece of cardboard large enough to hold a screen on top of.
Step 6. Place the silk screen under the UV lamp
Direct UV light will allow the emulsion to transfer the pattern from the stencil template to the silk screen. While it is possible to expose the screen to direct sunlight, using a controlled light source (such as a 150 watt UV lamp) will give you better control over the process. Refer to the instructions on the emulsion packaging for the exact UV exposure time.
The whole process can take from 10 minutes to several hours
Step 7. Carefully monitor the state of the screen and remove it from the light after the specified time
The exposure time should correspond as closely as possible to that specified in the instructions. Overexposing the screen to light will make it impossible to cleanse it later. Underexposure will not give your screen enough time to transfer the drawing onto itself.
Step 8. Wash the screen before use
The silkscreen stencil will not be ready until you rinse off excess emulsion from it. Wash your screen in lukewarm or cool water. Wash it carefully, being careful not to scratch it. Make sure that the water flows under low pressure and use a soft cloth or sponge to rinse off the emulsion.
Advice
- For your first experience, choose simple designs for yourself and gradually move on to more complex ones.
- If you are preparing a stencil to use several different paint colors, you will need a separate stencil for each color.