Polyester screen printing mesh is a fine mesh fabric made from polyester fibers, widely used in screen printing. It serves as the medium through which ink is transferred onto the substrate (such as t-shirts, posters, or other materials). Polyester is the preferred material due to its excellent strength, durability, and resistance to chemicals and moisture. The mesh count and thread diameter determine the detail and thickness of the printed image, with high mesh counts suited for fine details and low mesh counts for thicker prints. Polyester mesh maintains uniform tension and consistency during printing, making it ideal for printing on textiles, ceramics, glass, and electronics.
PFM Screen now has more than 300 Sulzer P7100 & P7150 looms, Beninger warping machines, cleaning and setting equipment, laser cutting equipment, inkjet printing machine, quality inspection detectors and ultrasonic welding equipment for the production of high-quality polyester screen printing mesh. PFM Screen's polyester screen Printing mesh products are mainly monofilament printing mesh from 10 to 600 mesh, and common width is 127 cm, 165 cm, 260 cm, 330 cm, the widest can reach 365 cm, special width, specifications and color can be customized.
● High tensile strength and low elongation.
● Resilient yet flexible enough to be used for printing on irregular surfaces.
● Excellent water and solvent resistance.
● Wide ranges of mesh count for choice.
● Ideal for stencil makers and screen printers.
● Custom service can be supplied for different requirements.
Polyester screen printing mesh is an essential component in the screen printing process, influencing the quality, detail, and ink deposition of the final print. The mesh count, measured in threads per inch, is a key factor in determining the appropriate mesh for a specific printing application. Here’s a detailed look at various mesh counts and their typical uses:
1. Low Mesh Count (40-80)
Mesh Count Range: 40-80 threads per inch
Characteristics:
● Large openings between threads
● Allows for heavy ink deposits
● Suitable for thick or specialty inks
Applications:
● Bold Designs: Ideal for printing designs with large, solid areas of color.
● Textiles: Commonly used for printing on fabrics such as t-shirts, hoodies, and other garments, where a heavy ink deposit is desired for vibrant, opaque prints.
● Posters and Banners: Used for producing posters, banners, and other large-format prints where bold graphics and high opacity are needed.
2. Medium Mesh Count (100-160)
Mesh Count Range: 100-160 threads per inch
Characteristics:
● Balanced between detail and ink deposit
● Suitable for a wide range of inks
Applications:
● General-Purpose Printing: Versatile for various substrates including paper, cardboard, and textiles.
● Moderate Detail: Suitable for designs with a mix of fine lines and larger areas of color.
● Signs and Decals: Used for printing signs, decals, and other items that require a moderate level of detail and ink coverage.
3. High Mesh Count (200-305)
Mesh Count Range: 200-305 threads per inch
Characteristics:
● Small openings between threads
● Allows for fine detail and precision
● Deposits thinner layers of ink
Applications:
● Fine Detail Work: Perfect for intricate designs and detailed images.
● Glass and Ceramics: Used for printing on smooth, non-porous surfaces like glass and ceramics, where precision is crucial.
● Electronics and Circuit Boards: Employed in printing applications requiring fine lines and high accuracy, such as in the production of electronic circuit boards.
The production process of polyester screen printing mesh involves several steps to ensure the final product meets the desired specifications for strength, durability, and precise mesh count. Here's a detailed overview of the polyester screen printing mesh manufacturing process:
1. Raw Material Selection
● Polyester Filament Yarn: High-quality polyester filament yarn is selected as the raw material. The yarn's characteristics, such as tensile strength, elasticity, and resistance to chemicals, are crucial for the final product.
2. Warping
● Yarn Arrangement: The polyester filament yarn is arranged on a warping machine to create the warp (lengthwise threads). This step ensures uniform tension and alignment of the yarns.
● Beam Preparation: The yarn is wound onto a warp beam, ready for the weaving process.
3. Weaving
● Loom Setup: The prepared warp beam is mounted on a weaving loom. The loom is configured to produce the desired mesh count and thread diameter.
● Weaving Process: The loom interlaces the warp (lengthwise threads) and the weft (crosswise threads) to form the mesh. The weaving pattern and tension are carefully controlled to achieve uniform mesh openings.
● Plain Weave: The most common weave pattern, where each weft thread crosses over and under each warp thread alternately.
● Twill Weave: A more complex pattern that can provide additional strength and flexibility, though less common in screen printing meshes.
4. Heat Setting
● Stabilization: The woven mesh is subjected to a heat setting process. The fabric is heated to a high temperature and then cooled. This process stabilizes the mesh, ensuring it retains its dimensions and properties under different conditions.
● Stress Relief: Heat setting also relieves internal stresses in the polyester fibers, improving the mesh's durability and consistency.
5. Surface Treatment
● Calendering: The mesh may undergo calendering, where it is passed through rollers to smooth the surface and improve uniformity.
● Chemical Treatments: Various chemical treatments can be applied to enhance properties such as ink adhesion, water repellency, or antistatic behavior.
6. Inspection and Quality Control
● Visual Inspection: The mesh is inspected for defects such as broken threads, uneven weaving, or inconsistent mesh counts.
● Mesh Count Verification: The mesh count (threads per inch) is checked to ensure it meets specifications. This is done using precise measuring tools.
● Tensile Strength Testing: Samples are tested for tensile strength to ensure the mesh can withstand the stresses of screen printing.
7. Cutting and Packaging
● Cutting to Size: The mesh is cut into standard roll sizes or custom dimensions based on customer requirements.
● Packaging: The cut mesh is rolled and packaged to protect it during transportation and storage. Packaging may include plastic wrapping, cardboard tubes, and outer protective materials.
8. Shipping
● Distribution: The finished mesh rolls are shipped to customers, ready for use in various screen printing applications.
