In the printing industry, especially when it comes to printing on T-shirts, textiles, and other soft substrates, plastisol ink is an indispensable material. Among them, opaque plastisol ink is highly favored by designers and printers due to its high opacity and rich color performance. This article will delve into how to properly use opaque plastisol ink and introduce several related special inks, including neon plastisol ink, old gold plastisol ink, over-curing plastisol ink, and pantone plastisol ink.
I. Understanding the Basic Characteristics of Opaque Plastisol Ink
Opaque plastisol ink boasts high opacity, capable of producing vivid colors on various colored substrates. It primarily consists of resin, pigments, plasticizers, and fillers, exhibiting good ductility and chemical resistance. This ink is applied through screen printing and is suitable for printing on multiple materials, including cotton, polyester, nylon, and more.
Proper use of opaque plastisol ink hinges on understanding its basic operation methods and precautions. From ink formulation and mixing to parameter adjustments during the printing process, every step is crucial.
II. Ink Preparation and Mixing
1. Ink Formulation
Correct formulation is key before using opaque plastisol ink. Typically, ink formulation should follow the manufacturer’s guidelines. Generally, plastisol ink needs to be mixed with an appropriate amount of hardener to ensure the durability and adhesion of the printed product.
2. Thorough Mixing
After mixing the ink and hardener, a mixer or manual stirring rod must be used for thorough mixing to ensure complete integration. Insufficient mixing can lead to uneven curing of the ink during the printing process, affecting the final result.
III. Printing Techniques and Tips
1. Screen Mesh Selection and Adjustment
The mesh count of the screen directly affects the printing effect. When using opaque plastisol ink, a screen with a slightly lower mesh count is usually required to ensure ink passage. At the same time, ensuring the screen is clean and unclogged is fundamental to print quality.
2. Use of Squeegee
The angle, pressure, and speed of the squeegee all influence the print quality. When using opaque plastisol ink, a squeegee with an angle between 45° and 60° is typically chosen, with appropriate pressure and speed for printing to ensure even distribution of the ink on the screen.
3. Adjusting Printing Pressure
Printing pressure is a critical factor affecting ink penetration and adhesion. When printing with opaque plastisol ink, the pressure of the printing machine needs to be adjusted according to the material and thickness of the substrate to achieve the best printing effect.
IV. Application and Precautions of Special Inks
1. Neon Plastisol Ink
Neon plastisol ink features bright colors and high luminance, creating unique visual effects in low-light or nighttime environments. However, the printing process for this ink requires higher precision in screen and squeegee adjustments to avoid uneven color or overflow.
2. Old Gold Plastisol Ink
Old gold plastisol ink presents a vintage and elegant gold color, suitable for creating high-end, sophisticated printed products. During printing, special attention needs to be paid to controlling the viscosity and curing time of the ink to ensure color consistency and durability.
3. Over-Curing Plastisol Ink
Over-curing is a common issue in plastisol ink printing. When the ink is subjected to excessively high temperatures or prolonged baking during the printing process, it can become brittle and prone to falling off. Therefore, when using opaque plastisol ink, it is necessary to strictly control the curing temperature and time to avoid over-curing.
4. Pantone Plastisol Ink
The Pantone color system is internationally recognized as a color standard. Using Pantone plastisol ink ensures that the color of the printed product matches the color sample provided by the designer exactly. Special attention should be paid to color accuracy and consistency during printing to avoid color differences.
V. Распространенные проблемы и решения
1. Uneven Ink Curing
Uneven curing is usually caused by insufficient ink mixing, improper curing temperature or time settings. The solution is to ensure thorough mixing of the ink and adjust the curing temperature and time according to the actual situation.
2. Blurred Edges on Printed Products
Blurred edges may result from a too-high screen mesh count, excessive squeegee pressure, or too-fast printing speed. Adjusting the screen mesh count, squeegee pressure, and printing speed can effectively solve this issue.
3. Ink Adhesion
Ink adhesion usually occurs during the drying process after printing. To avoid this, printed products should be immediately sent to the oven for drying after printing, with the oven temperature and humidity controlled.
VI. Техническое обслуживание и уход
1. Screen Cleaning and Care
The screen is one of the most important tools in the printing process. After use, it should be promptly cleaned to remove residual ink and impurities, thereby extending the screen’s lifespan.
2. Ink Storage and Management
Opaque plastisol ink should be stored in a cool, dry, well-ventilated place, avoiding direct sunlight and high temperatures. Regularly check the shelf life and quality of the ink to ensure the use of qualified ink for printing.
3. Printer Maintenance and Care
The printer is the core equipment in the printing process. Regular maintenance and care of the printer can ensure stable operation, improving printing efficiency and quality.
VII. Innovative Applications and Future Trends
With the continuous advancement of technology and consumers’ increasing demand for personalization, the application fields of opaque plastisol ink are continually expanding. From traditional T-shirt printing to high-end fashion apparel, home decor, and other fields, opaque plastisol ink demonstrates great potential and value.
Meanwhile, with the heightened awareness of environmental protection, more and more plastisol ink manufacturers are developing eco-friendly inks to reduce environmental pollution. In the future, eco-friendly, efficient, and personalized opaque plastisol ink will become new trends in industry development.
VIII. Заключение
Proper use of opaque plastisol ink requires not only mastering basic printing techniques but also understanding the characteristics of the ink and solutions to common problems. By reasonably selecting screens, squeegees, and printing parameters, as well as strictly controlling the curing temperature and time, the quality and color effect of the printed product can be ensured. Additionally, paying attention to ink storage and management, printer maintenance and care, as well as innovative applications and future trends, can help printers continuously improve their competitiveness and professionalism.
