Printing techniques were summarized including: 1. Printing involves applying dyes or pigments locally to fabrics to create designs through techniques like screen printing and block printing. 2. Screen printing uses a mesh screen to block ink from transferring in some areas to create sharp-edged images, while block printing carves designs into wooden blocks. 3. Other techniques include discharge printing which dyes the whole fabric and then removes dye in a pattern, and resist printing which applies a dye-repelling substance before dyeing.

1. Printing Techniques
Presented by:
S.Rajesh Kumar
PSG TECH
E-mail: srk3rajesh@gmail.com

2. PRINTING
• The printing is described as localized dyeing, dyes or pigment are applied locally or
discontinuously to produce the various designs.
• Printing is the production of all active designs with well defined boundaries made by the
artistic arrangement of a motif is one or more colors. Printing is a process for reproducing
text and image, typically with ink on paper using a printing press.
• Screen printing is a printing technique that uses a woven mesh to support an ink-blocking
stencil. The attached stencil forms open areas of mesh that transfer ink as a sharp-edged
image onto a substrate.
• Screen printing is also a stencil method of print making in which a design is imposed on a
screen of silk or other fine mesh, with blank areas coated with an impermeable substance,
and ink is forced through the mesh onto the printing surface. It is also known as silk
screening or serigraphy.

3. Direct Printing:
In direct printing a design is etched into a copper roller. A dye that has been
thickened into a paste with starch, gelatin, or synthetic polymers is applied to the etched
area while the un-etched surface is kept clean.
The color design is transferred to the cloth under pressure. Direct printing may
also involve forcing the paste onto the fabric through a screen, a technique similar to
stencil printing except that the screen controls how much paste is applied to the cloth.
DIFFERENT STYLES OF PRINTING

4. Direct Printing

5. Resist Printing:
In resist printing a reverse-printing method, a dye repelling
substance is selectively applied to the cloth, which is then placed in a
dye bath. This method is used for example, to produce white polka dots
on a color background.
Discharge Printing:
In discharge printing, the whole fabric is dyed. A pattern is then
printed on the fabric with a chemical that oxidizes or reduces the dye,
creating a white pattern on a colored background.

6. Discharge Printing

7. Discharge Printing

8.  Roller Printing
 Flat (Silk) Screen Printing
 Rotary Screen Printing
 Block Printing
 Heat Transfer Printing
 Dye Sublimation Printing
 Resist Printing

9. Automatic Print Hand Print
1. Accuracy 1. No Accuracy
2. Limited Production 2. No Limited Production
3. Production is high 3. Production is Low
4. Depends on m/c capacity 4. It is manually print
5. Capacity is 9 colors 5. Variety colors print
Difference between Automatic Print & Hand Print

10. Printing methods
Digital printing
• Ink-jet printing
Heat-transfer printing
• Design transferred to fabric from specially printed paper by heat & pressure
Electrostatic printing
• Prepared screen covered with powdered dye; passes through electric field & pulled
onto material
Foil printing
• Adhesive applied to fabric, foil heated on heat transfer press & bonds to adhesive
pattern
Stencil printing
• Separate pattern cut for each color, color is applied in thick paste or sprayed on with
air gun

11. Factors Affecting Cost of Printing
1. Size of printing
2. Number of color of printing
3. Any grading of size of printing from size to size
4. Any restriction/selection of use of dyes and chemicals
5. Lab test requirement
6. Wash sustainability
7. Tolerance in placement of print art-work
8. Tolerance in color shade variation
9. Place of printing
10. Type of printing

12.  Preparation of the fabric to be printed
 Preparation of the print paste
 Making an impression of the print paste on the fabric
 Drying of the printed fabric
 Steaming of the printed fabric
 After treatments (soaping etc)
Steps of printing
Design
↓
Expose
↓
Color
↓
Develop sample
Steps of printing section

13. Block Printing
• It is the oldest and simplest way of printing
• In this method a wooden block with a raised pattern on the surface was dipped into
the printing colorant and then pressed face down on to fabric.
• The desired pattern was obtained by repeating the process using different colors.
• Generally the wooden block is carved out of hand
• Printing is done manually

14. BLOCK PRINTING

15. BLOCK PRINTING
ADVANTAGES
1. Simple method of printing
2. No expensive equipment required
3. No limitation in repeat of size of style
4. Prints produced have great decorative value and stamp of craftsmanship
DISADVANTAGES
1. Involves much manual work
2. Method is slow and therefore low output
3. Good skilled labors needed for multi color design
4. Fine and delicate designs hard to produce

16. ROLLER PRINTING M/C

17. Diagram of roller printing m/c

18. ROLLER PRINTING
ADVANTAGES
1. Large quantities of fabric at the rate of 914-3658m per hour can be printed.
2. Faulty joints or joint marks are absent.
3. Fine sharp outlines and good prints can be obtained which is difficult to get in block
printing.
DISADVANTAGES
1. Not economical for short run of fabrics.
2. Difficult to produce blotch designs.
3. Repeat of design limited to the size of the rollers.
4. Setup cost of roller printing m/c is high

19. STENCIL PRINTING
• It is one of the oldest way of printing.
• In it color is applied to the fabric by brushing or spraying the interstices of a pattern
cut out from a flat sheet of metal or waterproof paper or plastic sheet or laminated
sheet.
• A stencil is prepared by cutting out a design from a flat sheet of paper, metal, or
plastic.

20. A simple stencil design

21. Example of stencil printing

22. STENCIL PRINTING
ADVANTAGES
1. Simple and cost effective.
2. Stencils can be made rapidly and can be used for small orders.
3. Color combination is good in it.
DISADVANTAGES
1. Good design is difficult to obtain.
2. Process is laborious.
3. Not suitable for large scale production.

23. SCREEN PRINTING
• It involves the application of the printing paste through a fine screen placed in
contact with the fabric to be printed.
• A design is created in reverse on the screen by blocking areas of the screen with a
material such as an opaque paint.
• The screen is then placed over the fabric and the printing paste is forced through the
open areas of the screen using a flexible synthetic rubber or steel blade known as a
squeegee.

24. PROCESS OF SCREEN PRITING
SCREEN PAPER SIDE SCREEN SQUEEZE SIDE
ORIGINAL PRINT PRINT ON FABRIC

28. SCREEN PRINTING
ADVANTAGES
1. Simple and cost effective.
2. Quick pattern making
3. 16 colors can be used in a design.
4. Sharp lines and features easily produced.
DISADVANTAGES
1. For high production large no. of tables required.
2. Delicate shading difficult to obtain.
3. Screen clogging may be there in fine areas.

29. FLAT-SCREEN PRINTING
• It is the advanced version of screen printing by using automatic m/c to do work
• It consists of printing table, conveyor belt, number of screens, mechanism to print
on the fabric, etc.
• First the fabric is brought on the printing table through a feeding arrangement and it
is gummed to the conveyor belt on the table
• Conveyor brings fabric periodically under screen and stops while the screen are
lowered on the required parts of the fabric.
• Printing paste is distributed throughout the full length of the screen.
• The squeeze is pressed to the screen .
• One or more strokes of the squeeze ensure simultaneous printing of the pattern by
the common action of all screens which applies printing paste as required by the
color in the design.

30. FLAT-SCREEN PRINTING M/C

31. FLAT SCREEN PRINTING
ADVANTAGES
1. Greater production than manual screen printing
2. Printing with different repeat can be made easily
3. Good print is obtained
DISADVANTAGES
1. A big setup required for more number of screens
2. Prints with more colors may not be possible
3. Printing paste not evenly controlled

32. • This process involves a print paste (like a thick paint) that is applied to an engraved
roller, and the fabric is guided between it and a central cylinder.
• The pressure of the roller and central cylinder forces the print paste into the fabric.
Because of the high quality it can achieve, roller printing is the most appealing method
of printing designer and fashion apparel fabrics.
• Long runs of the same fabric design are produced on a roller print cylinder machine
operating at speeds between 50 and 100 yards a minute. As many as 10 different colors
can be printed in one continuous operation, but each colour must have a separate roller.
• The design is cut into the surface of copper rollers; by varying the depth of the
engraving on the roller the shade depth can be altered.
Rotary Screen Printing

33. •Sharpness of line and fine detail can be achieved this way. A typical printing machine
has a large padded drum or cylinder, which is surrounded by a series of copper rollers,
each with its own dye trough and doctor blade that scrapes away excess dye.
•The tubular screens rotate at the same velocity as the fabric, the print paste is
distributed inside a tubular screen, which is forced into the fabric as it is pressed
between the screen and a printing blanket (a continuous rubber belt). It picks up colour
from the engraved area of each roller in sequence.
•The printed cloth is dried immediately and conveyed to an oven that sets the dye.
Knitted fabric is mostly printed in this method as it does not pull or stretch the fabric.

34. Rotary Screen Printing Process

37. Screen mode (50-60 min dryer temp 70 c)
↓
Exposing mc
↓
Cold water (5 min)
↓
After them spray gun develop
↓
Dryer (30-40 min)
↓
Re-wash
↓
Dryer (20 min)
↓
Re-expose (20 min)
↓
Hard & applied.
↓
Design complete
Steps in design to screen:-

39. TRANSFER PRINTING
• It is a indirect method of printing in which dyes are transferred from paper to a
thermoplastic fabric under controlled conditions of temperature, time and pressure.
• The image is first engraved on a copper plate.
• Then pigment is applied on these plates.
• The image is then transferred to a piece of paper, with a layer of glue applied .
• This is then placed on the fabric and heat and pressure applied which fixes the print
onto fabric.

42. TRANSFER PRINTING
ADVANTAGES
1. Operation is simple and no expensive m/c is required.
2. No after treatment of fabric required
3. Print on fabric is of excellent quality
DISADVANTAGES
1. Process applicable to synthetic fabric like polyester .
2. Color range is limited.
3. Cost of printed paper high.
4. Not economical for small orders.

43. • Dye sublimation allows photo lab quality picture printing. During the dye sublimation
printing process, an image is digitally printed in reverse with dye sublimation toners or inks
onto media.
• That image is then placed on top of a fabric and subjected to high heat and pressure to
form a heat press.
• The dye sublimation toners or inks sublimate – the inks go from a solid state to a gaseous
state without becoming liquid in between and flow into the fabric, dyeing the threads.
• This creates a gentle gradation of colour and does not distort or fade over time.
Dye Sublimination Printing

44. RESIST PRINTING
• There are two types of resist printing
1) BATIK PRINTING
2) TIE & DIE PRINTING

45. BATIK PRINTING
• Originated on island of Java and is a cottage based industry.
• Batik is derived from word “AMBATIK”
• The resist-dyeing process, whereby designs are made with wax on a fabric which is
subsequently immersed in a dye to absorb the color on the unwaxed portions, is
known as batik printing.
• Special feature is the fine lines of color running irregularly across the fabric.

47. Dyeing fabrics
Industrially-produced
Batik
HOW IS IT DONE?
• Gum, wax-resist paste or resin is printed on
the fabric from hot rollers
• Fabric is dyed
• Heat finished to remove surplus gum or wax
and fix the dye
• Alternatively, batik patterns can be printed
on fabric from engraved rollers using
photographic methods or CAD/CAM
Hand-produced Batik
HOW IS IT DONE?
A design is drawn on fabric with melted wax
using a brush or tjanting and left to harden,
fabric is then brush or dip dyed and the wax
melted off using an iron. The dye resists
penetrating the fabric under the wax leaving a
patterned fabric.

48. BATIK PRINTING
ADVANTAGES
• Gives a good artistic effect
• Cheap printing
• Greater artistic design
• Fabric has a rich and graceful
appearance
DISADVANTAGES
• Laborious
• Time taking
• Cracking effect
• Dye should be applied at low
temperature than wax.

49. A resist method of dying where fabric of finished garments are either
twisted, knotted, gathered or crumpled and then bound with string or
elastic bands before dyeing.
Produces a variety of patterns. Garments made using tie dye come in
and out of fashion.
TIE & DYE

50. • It is same as that of batik printing but here the dye is resisted by knots that are tied
in the cloth before it is immersed in dye bath.
• The outside of the knotted portion is dyed, but inside is not penetrated if the knot is
firmly tied.
• This gives a characteristic blurred or mottled effect .
ADVANTAGE
• Interesting design created on fabric
• No m/c cost is there
DISADVANTAGE
• Costly
• Laborious
• Time taking
• Skilled labour required

52. Burnout Printing
Burn-out textiles is a technique used to develop raised designs on fabric surface. This is
primarily being done in fabrics with at least 2 different fibre content i.e. Cotton-
Polyester, Silk-Rayon etc. Here one fibre component is being dissolved thru chemical
reactions while the other content remains intact giving away raised illusion designs.

53. 1. This involves printing with a chemical that will destroy the fiber in the
patterned design print area.
2. In fabrics that are made with blended yarns, the burn-out chemical will destroy
one fiber and leave the other undamaged. Unusual and interesting fabrics can
be created by this method.
Burn-out Prints

54.  Tiny particles of fiber are made to adhere to a fabric surface in conformance to a
particular design. Rayon and nylon fibers are typically used for flocking.
 The ability of flocked fibers to withstand dry cleaning and/or laundry depends on
the adhesive. Adhesives with excellent fastness to cleaning processes are used.
Flock Prints

55. Puff print
Foil print
Flock print
Duplex Prints

57. Marketing Printing - Digital
Printing
Iris Graphics
STORK
Toxot Imaje
Jemtex
STORK
Epson
Konica
Xaar
Spectra
Hewlet Packard
Canon
Lexmark
Ink-jet systems
Continuous flow Drop-on-demand (DOD)
Binary
deflection
Multiple
deflection
Mechanical
Piezo - activated
Thermic
"Bubble Jet"
• Differences in the selection and generation of droplets
Ink-jet systems

58. Lighter Print Faults in Textile Screen Printing on Fabric:
 Lighter shades on Selvedge and gradually deeper towards the other.
 In the middle of the fabric and darker towards the selvedges.
 While using large amount of foam.
 Due to uneven application of Gum.
Darker Screen Printing faults:
 May be obtained irregularly throughout the fabric.
 If a soft table is used on a hard table surface.
 If a hard squeeze is used on a soft table surface.
 Deep stripes along the warp.
 Very small specs of color on the ground (Unprinted Portion).
 Screen may get clogged during working.
Difficulties in printing:

59. Printing faults:
1. Print color shadin
2. Print slarted
3. Color spot
4. Bleeding
5. Print wrong
6. Print burn
7. Air hole
8. Print bubble
9. Print missing
10. Wrong place
11. Not properly attached
12. Hand feels
13. Migration
14. Dirty mark
15. Uneven shade
16. Shade variation
17. Print sticky
18. Print not coverage
19. Print gap
20. Print over
21. Wrong side
22. Color wrong
23. Size mistake
24. Bunoledle card mistake
25.Fabric h
26.Fabric shade
27.Crease mark
28. Oil spot
29. Fabric burn
30.Needle mark
31. Cutting problem
32. Sticker wrong
33. Dye migration
34.Yarn hole
35. Yarn contamination
36. Fly yarn.

60. Thank you