June '19

For the Business of Apparel Decorating

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2 0 1 9 J U N E P R I N T W E A R 1 7 TRAINING in the HALL Please visit for more information. Experience the lively exhibit hall, the classes taught by industry experts and the endless networking opportunities, all conveniently located near you! Long Beach, CA August 15-17, 2019 TRAINING STOP Anything white in the original has no information to work with. We duplicated the Cyan channel as it had the least amount of white with tones to help define. We inverted it and removed the info from around the ball. This information was reversed and would be the positive area for the white. Just as we did on the black, using Levels, we blew out some of the lower tones. By removing that info, the garment would play a role in color- izing the ball. To create some texture and motion for the design, in the Filter menu and Filter Gallery option clicked for the new dialog box we could preview filters as they would be applied. We chose Rough Pastels for a grain like a pastel chalk. Our image was 300 dpi so when we used the filter, it had a minimal effect because of the fine resolution. The trick was to duplicate the file where we reduced the resolution to 96 dpi. Then, when the filter was run it produced desirable results. Since the files of the ball were duplicated for the effects, they had to be brought back into the original file for output and scaled up to match the original elements. Using the ball shape itself, we made a selection and did a stroke around the edges so it closed up any open or misaligned areas. The last element needed was the school name and sport. A clean, athletic font did just the trick and was laid right over the top of the soccer ball, completing the design with satisfactory approval from our customer. We mustn't forget the white printer or base plate since this is going on purple gar- ments. Some of the white had halftones from the info we extracted from the duplicate channels we used to run the filters over. The most solid areas needed a full base to keep them brightest. We also like to have some of those halftones come down directly on the fabric to give us secondary tones influenced by the garment color, getting a little extra without adding a screen. Using Levels once more, we blew out just enough to go a little further with variation of tones. Once LHS approved our digital mock up, we proceeded to the rest of pre-press. We outputted from Illustrator to CTS and kept the halftone frequency an easy 45 lpi. The garments were polyester performance fabric, so we used lower cure inks designed to cure in the 270 degree range, keeping the poly at lower temperatures in hopes that the dyes in the fabric would not release, thus minimizing bleed. First, we printed the black followed by a bleed blocker on an 83/70 (83tpi with a 70u thread). After flashing and smoothing, making sure not to exceed the gel temp on press, we printed the whites and colors on 180s. All the screens were quality-dyed mesh stretched on retensionable frames and stabilized at 30 N/cm2. Setup was simple using our pre-registration system. After just a small micro adjustment we were good to go. Squeegees were all sharpened triple- ply dual durometer 65/90/65s at a medium pace and 15-degree angle. We set our dryer belt speed to have a full minute in the chamber and reach a tempera- ture of 270-280 degrees F for at least 10 seconds. At the end of the dryer we set up fans to help cool so we could stack side by side, so as not to stack hot shirts on top of one another in an attempt to keep the poly as cool as possible. PW Lon Winters learned screen printing from the bottom up, starting his 20-plus-year career reclaiming screens. He has won nearly 50 international industry awards and honors, published numerous articles, and led several industry seminars and workshops. Currently, he is president of Colorado-based Print This, Inc./, an international consulting firm specializing in technical advances, plant design, layout, troubleshooting, productivity, quality analysis, and complete garment- embellishing solutions. Visit for more information. Contact Winters at

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