Choosing the mesh and screen tension

In short: the mesh count (threads per cm) largely determines ink deposit and detail: a fine mesh deposits little ink and renders fine details, while a coarse mesh deposits a lot of ink for solid areas and textiles. Screen tension, in turn, controls sharpness, registration and the screen's lifespan.

Choosing the screen printing mesh by use: from coarse 16T to fine 120T, and screen tension above 16 N/cm — Recommended mesh by use and target screen tension.

So you choose the mesh to suit the substrate you want to print, but also the type of ink you will use.

The steps

1. Define the target result

Textile solid area, fine details, thick ink (puff), process (CMYK), or special inks (glitter, for example).

2. Choose the mesh accordingly

Coarse mesh for textile solids, fine mesh for details.

3. Check the screen tension

With a tension meter; target value in N/cm depending on the frame and mesh.

4. Record the validated mesh + tension pair

So you can reuse it on your next prints.

Recommended mesh by use

Values in threads/cm. In the US, values are given in threads/inch: multiply them by 2.5.
Use	Starting mesh	Deposit / result	Setup notes
Glitter, large pigments	16T-25T	Very high deposit	Check the grain size: the pigment must pass without clogging the mesh.
Puff, high density, very opaque white	32T-43T	High deposit	Often used with 15-20% EOM and a 60-70 shore squeegee.
Standard textile solids	43T-61T	Medium to high deposit	Good starting point for cotton, plastisol or opaque water-based ink.
Textile details, colours on a white base	77T-90T	Moderate deposit	Improves hand feel and sharpness, and reduces fibrillation.
Halftones, textile CMYK, fine paper	90T-120T	Fine deposit	Pair with a dense film, good tension and a 75-80 shore squeegee.
UV, labels, smooth substrates, electronics	120T+	Very fine, controlled deposit	Requires high tension, a clean environment and a suitable ink.

Frequently asked questions

Which mesh for a t-shirt?

For a textile solid, start around 43-61 threads/cm; for an opaque white or a puff, go down to 43 threads/cm; for details and halftones, go up to 77T-110T.

Which mesh for which ink?

Match the mesh opening to the ink type, to account for its viscosity but above all its drying in the mesh: the faster an ink dries, the more open a mesh you choose. On textile, for example, use a more open mesh for a water-based ink (43-54) than for a plastisol (54-77).

Why does good tension reduce smearing?

A tensioned mesh snaps off the substrate quickly behind the squeegee, without dragging in the wet ink. It needs less pressure and distorts the image less. Always use a sufficiently tensioned frame, with a suitable off-contact (the gap between screen and substrate).

Why does my tension drop over time?

The mesh slackens naturally with use; a slack frame harms registration and must be re-tensioned or replaced.

Advanced details Screen tension

Parameter	Recommended baseline	Why
Tension	> 16 N/cm minimum for effective mesh release after the squeegee stroke	Improves sharpness, registration and peel, and reduces the required pressure.