In this episode of Let’s Talk Shop, we sit down with Kevin Kauth from Chromaline to talk about screen room consistency, exposure best practices, and where screen printing is heading.
On-the-Job Training vs. Formal Education
Kevin notes that screen printing does not have a traditional school in most regions, most printers learn from mentors on the job. That can work, yet it sometimes turns into a game of telephone as tips morph over time. If you want structured learning to complement shop experience, explore our screen printing classes and courses for hands-on training and proven workflows. Even seasoned printers with decades of experience pick up new wins when they revisit the basics.
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The Importance of the Screen Room
Screen printing is called screen printing for a reason, the screen is the foundation of every good print. Kevin stresses the importance of consistency at every step, reclaiming, coating, drying, and exposing. If variables shift in the screen room, printers will see inconsistent results on press. To standardize exposure from day to day, build around a quality exposure unit and work under UV-safe yellow darkroom bulbs.
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Key Acronyms Explained
- EOM: Emulsion Over Mesh. The stencil thickness in relation to mesh thickness, ideally around 10 to 20 percent for durability and detail. Choosing the right emulsion and coating method helps you hit target EOM.
- LTS: Laser-to-Screen. Imaging technology that uses lasers instead of film to directly expose designs onto screens.
- CTS: Computer-to-Screen. Imaging that prints artwork directly onto emulsion-coated screens, often with wax or inkjet heads.
- DTF: Direct-to-Film. A digital transfer process where designs are printed onto a film and heat pressed onto garments.
- DTG: Direct-to-Garment. A digital printing process that prints directly onto the fabric.
Common Screen Room Mistakes
According to Kevin, many shops underexpose their screens. This happens because printers worry about losing detail, yet underexposure leads to soft stencils, reduced durability, and unnecessary breakdowns. The fix is simple, run exposure tests regularly with tools like an exposure calculator, and adjust for humidity and temperature changes. Pair that with consistent coating, an automatic coater or SAATI ProCoat 25x36 can tighten variance fast.
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Industry Trends, Technology and Techniques
Kevin sees screen imaging technology as the biggest change in recent years. The shift from inkjet films to laser based systems has transformed detail, alignment, and repeatability. Digital options like DTF surged in popularity, yet screen printing remains a powerhouse for durability and quality at scale. If you are setting up for volume, start with quality screens such as Baselayr aluminum screens and a dependable exposure unit.
Building a Strong Screen Room
For new printers, Kevin emphasizes investing in a reliable exposure unit early. DIY is possible, yet often inconsistent. Plan a darkroom a little larger than you think you need, capacity grows quickly, and workflow thrives with space. Round out your setup with the right emulsion, quality reclaim chemistry like Bluewater Labs Inline Reclaim Series, and UV safe darkroom bulbs to protect your stencils.
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Best Practices from the Emulsion Guru
- Reclaim thoroughly, dirty screens mean weak stencils. Use strong, shop safe chemistry such as Bluewater Labs Reclaim.
- Automate coating if possible for consistency with an automatic coater or dual screen auto coater.
- Dial in exposure times with a step wedge exposure calculator, run tests as seasons change.
- Maintain consistent stencil thickness with the right emulsion and coating settings to hit target EOM.
- Start with quality screens like Baselayr aluminum screens for repeatable tension and durability.
- Work under UV safe yellow darkroom bulbs to reduce accidental exposure.
Why Consistency Wins
The best screen rooms are not defined by size or budget, they are defined by consistency. Repeatable processes lead to predictable results, and predictable results fuel growth for shops of every size. If you are ready to standardize, begin with an exposure unit, choose the right emulsion, and validate with an exposure calculator.
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Your creativity deserves the best tools. Take these insights to your shop, build consistency, and watch your prints reach the next level.