FAQS

What is the difference between silk screening and screen printing?

People use these terms interchangeably in reference to the screen printing process. The screens used in the early days of printing were made of silk. It’s been decades since silk has been used, so the proper term is “screen printing” Serigraphy is the art of making prints with the screen printing process.

What is screen Printing?

Screen printing is a process though which ink is mechanically applied to a substrate via the use of a screen and squeegee. In it's basic form, screen printing is a very simple process. How ever, we use the most advanced machines to speed up the process and ensure consistency. You can learn more about this on the “Process page”.

What is spot color?

Spot-Color is the term used to describe separation and printing with one ink color for every color in the design. Each color that makes up the composite image will be printed using a separate screen.

What is 4 - color process ?

4-color process is a more advanced separation and printing technique that uses 4 colors of transparent ink to produce the colors from the original design. The four colors, Cyan, Magenta, Yellow, and black ( CMYK ), are printed as halftones that interact with each other and the white background of the shirt to create color and tonal values. A wide spectrum of colors can be represented but some colors are impossible to produce.

4-color process is used mostly for photographic or digitally created designs because many shades and colors can be created with only four screens. High screen counts and screen frequencies are required to create the tiny halftone dots.

The draw back in the past was that you could only print 4-color process on white or light color garments. Since then we have developed processes that have allowed us to print this process on black as well as all other colors. Often though, Simulated Process is better for prints on dark color garments.

What is simulated process printing?

Simulated Process is another advanced technique that uses halftones of a few ink colors to represent the colors in the original design. This process differs from 4-color process in that the inks are solid opaque colors usually printed on dark colored shirts. Because the shirts colors are normally dark, simulated process generally requires the use of an under base.
When working with simulated process, we start with a digital design or one that is scanned into the computer. The image can range from something that is photo-realistic to a line drawing or illustration. Once in the computer at the correct size and resolution, we process the design through a special program that automates the difficult separation process. . Currently we use a program called Separation Studio designed specifically for screen printers. We work closely with the developers of this software. With better prepared art we create the separations in Adobe Illustrator. We will end up with 5 to 12 color channels to work with. Now, we must adjust these channels so that the final print on the shirt will match the original artwork. This is the part that takes skill and applied experience from our art department. Once the adjustments are finished, the separations are printed out as usual.
Simulated process requires relatively high mesh counts and screen frequencies. We generally use 230-355 mesh and 55-65 lpi separations. Depending on the design, 3 to 9 or more ink colors may be needed to accurately reproduce all subtle color variations.

What is index color?

Index color is another separation and printing technique that uses a few ink colors to produce a full color print. Unlike 4-color and simulated process, index color does not use halftones. Rather, the design is broken up into tiny square areas of solid color. These squares are very small ( 200 per inch ) and when printed they blend together to trick the eye into seeing color shades and variations.


Index color works well on both white and colored garments but generally takes more ink colors to represent a design with lots of color variation. Index color has the added advantage that you can pick the exact ink colors to use. This way you can more accurately represent colors that are difficult to produce using a "process" method. It also requires high mesh counts to print the tiny squares properly. We generally do not use index as we get better results from our own hybrid of simulated process printing.

What are half tones?

Halftones are a pattern of tiny dots that can simulate different shades of color using varying percentages of a single ink. Visually, halftones create the illusion of a continuous tone image by using spots of varying size and density to represent darker or lighter color values.
Halftones work by fooling the eye into seeing the combination of the ink color and the color of the shirt they are printed on. When seen from a distance, the colors blend together and the dots merge with the background color of the shirt. If you look closely at or magnify the print, the separate dots are quite clear. You can see good examples of halftones if you magnify a picture in a magazine or a print from a color printer or even if you look closely at your TV screen. All these are made up of tiny dots.
In screen printing we use halftones for three main purposes: 1. To create a tint or lighter shade of a color. This will allow more "colors" in the design without adding more screens. 2. To create a gradient or the appearance of a continuous tone of color. 3. To create overlapping screens of different ink colors that combine to simulate more colors.

What is line count, screen frequency, and lpi?

These terms all refer to the number of vertical lines of halftone spots per inch or lines per inch (lpi). Halftones are created using a grid of cells. Each cell contains one halftone spot. These spots vary in size depending on the shade of color being represented but only one fits in a cell. The size of these cells determines the lpi. Various lpi numbers are used for different types of printing. Magazine pictures may have 100-130 lpi, newsprint is typically 85 lpi, a 300 dpi laser printer is around 55 lpi, and billboards might be 3-6 lpi. When we are using halftones for screen printing we use 45 lpi for basic designs and 65 lpi for detailed and process type designs.
The correct lpi to use is a function of the detail you want to produce and the distance from which a print will be viewed. When reading a magazine, the 100 lpi halftones will be invisible at 12 ". Likewise, if you view a 45 lpi t-shirt print from 3-4 feet you won't notice the halftone dots.

What is screen count or mesh count?

The mesh count is the number of threads per inch (tpi) used to weave the mesh. Typical mesh counts for screen printing t-shirts range from 85 tpi to 355 tpi. The mesh count defines basically two things: The thickness of the ink deposit and the size ( or lpi ) of halftones that can be printed.
The lower mesh counts, 85-110 tpi, have a relatively large thread diameter and more space between the threads ( called "open area" ). This allows for a thicker deposit and more ink to pass through the screen. Typically, lower mesh counts are used for specialty inks ( like glitter ) and when a thick deposit is needed on dark garments.
The high mesh counts, 305-355 tpi, have a very small thread diameter and less open area. These are used when fine detail and high halftone lpi are needed.
In the middle, 200-255 tpi, are general purpose screens for spot color, good detail and acceptable halftones.

What is an under base?

An under base is a layer of ink, usually white, that is printed under the other ink colors when printing dark garments. When printing most colors on dark garments the color of the shirt will show through the ink slightly. For instance, yellow ink printed directly on a royal blue shirt will look very green. To prevent this, a thin layer of white ink is printed, then "flash" dried, and the yellow is printed on top. This gives the top colors a good neutral base and reduces or eliminates the shirt color showing through.

What is flashing or flash drying/curing?

Flash curing is the process of "gelling" a layer of ink with a spot heating unit while still on the press. To "gel" the ink layer the temperature is raised to the point where the ink begins to dry but is not completely cured. The ink will be dry to the touch and will form a solid surface to print additional colors on. When the garment is run through the drier the flashed layer will cure completely and bond to the ink layers on top to form a solid film.

How many colors can Airship print?

We can print up to 12 different ink colors at a time. However, we use several techniques to increase the number of perceived colors in a print. We can produce full color prints on both light and dark colored garments. ( See "What is 4-color process?", "What is simulated process?" and "What is index color?" for examples. )

How do I prepare art files for submission?

In a perfect world everyone has Adobe Illustrator and designs in “vector” This allows us to manipulate the image without loosing any detail. We accept .AI. .PDF, DCS 2.0. .EPS, and PSD files. We prefer them best to worst in that order. There may be an art fee if we have to prepare files made in Photoshop, MS pain, or Corel. Some Photoshop images in raster are acceptable but they need to be high quality images. Images “snagged” off the internet do not have enough detail to print. We will have to redraw and vector these at a fee.

What is a vector file?

Vector graphics is the use of geometrical primitives such as points, lines, curves, and shapes or polygon(s), which are all based on mathematical equations, to represent images in computer graphics. Simply, Vector graphics can be sized smaller and larger with out any loss of information.

What is raster?

In computer graphics, a raster graphics image or bit map is a data structure representing a generally rectangular grid of pixels, or points of color, viewable via a monitor, paper, or other display medium. Raster images are stored in image files with varying formats (see Comparison of graphics file formats). A bit map corresponds bit-for-bit with an image displayed on a screen, generally in the same format used for storage in the display's video memory, or maybe as a device-independent bit map. A bit map is technically characterized by the width and height of the image in pixels and by the number of bits per pixel (a color depth, which determines the number of colors it can represent). The printing and pre press industries know raster graphics as contones (from "continuous tones") and refer to vector graphics as "line work". We usually avoid using Photoshop since it’s main purpose is to manipulate photographs, create web safe images, and prepare files for offset printing. But for raster images, we will convert them into a .tiff file and separate them in a program that quantifies the image in vector elements.

What is dye sublimation?

Dye sublimation is a printing process that uses heat to transfer dye onto medium materials such as a plastic card, paper, or fabric. The sublimation name is applied because the dye transitions between the solid and gas states without going through a liquid stage. The image is heat transferred from a printed carrier sheet onto polyester fabric. This process is used in bicycle jerseys and sports jerseys.

Does Airship save the screens used to print my products?

No, we recycle the screens again and again. While we do catalog your films and digital files, we re-burn your screens for every job to ensure the detail is at it’s finest. Screens often loosen and become stretchy. So we re-stretch and re-burn as needed.

What does it mean to “Burn a screen”?

When your image is separated into color channels, a “positive” film is made for each color. That positive is then exposed photographically onto a screen that has been pre coated with a photo sensitive emulsion. The screen is then developed leaving a stencil that allows ink to pass through the screen in the correct places. We use the phrases Screen burning” and “screen exposure” interchangeably. The word “burn” is only a reference to the light exposure.

What is DTG or direct to garment printing?

Direct to garment printing is a process by which a large format computer printer like an Epson 4880 has been re-engineered to print water based t-shirt ink through the printer head onto a t-shirt. Dark shirts have to be pre-treated with a special chemical so that the inks look more vibrant. We have experimented with this process and found the inks to not be color fast and the “hand” or feel of the shirt to be sticky. It is basically a process like a heat transfer except you print the transfer onto the garment and then heat press it. The minimum cost is about ten dollars per shirt and takes several minutes in a best case scenario to print a single shirt. In comparison to screen printing, we generally print a shirt every 3-5 seconds. The only positive we have found about this equipment is to be able to print a single shirt with less set-up than screen printing. Since the ink only adheres to the surface of the fibers in the garment, the print is not very color fast and does not hold up to repeated washings. In screen printing the ink bonds all around the fibers in a microscopic level producing a print that should last the life of the shirt.

Do you heat transfer or print numbers on jerseys?

We are capable of doing both. While heat transfer is cheaper- some teams prefer printed numbers. We have a special press that only prints numbers.

Why should I send my business to Airship vs. other printers listed in the phone book?

We print on a level comparable to the biggest name brands, in fact we use the same machines and currently have the fastest press in the state and region. Everyone seems to know a guy printing out of his garage or a small shop. Heck, that’s where we started out. We grew quickly due to our attention to detail and keeping our deadlines. Often times, small shops do not have the best curing equipment. This is why you see shirts where the ink has fallen off in places in the washing machine. our dryer heats every garment for a full minute at 380 degrees or what ever temperature is appropriate for that material. It operates at 300,000 BTU so you can be sure your garment will hold up. The reason you should send your business to us is that even if we are a little higher in price than someone’s pal operating out of their basement or storage unit, we will do it right and offer you the most options. 30% of our business comes to us from customers who went elsewhere the first time and had to pay us to re-do it because the product failed or the printer was late. This means they wasted money. We also have direct relationships with our suppliers and often test new products for our vendors and help in development. Simply- if you want it done right, if you want it done well, call us.
We don’t like doing a bad job. We continuously re-educate our staff on new technologies in the industry and invest in newer better equipment so that we can deliver on what we sell.

Do you have minimums?

We try to keep a 24 piece minimum. But we often do orders for a single garment. This is not most economical choice for the customer- but many companies need single samples for catalogs before they launch a product line. Give us a call and let us know what your looking for and if we can’t do it for the price your comfortable with we will try to help you find someone that can.

Do you have a maximum limit?

No, we regularly do 10,000 piece and higher orders for marathons and races. For orders over 5000 pieces please call ahead to get on the schedule so you do not incur a rush fee.

How much is a rush order?

This is determined by size of order and time of year. Please contact us to get current rush fees.

How long do you need to print my order?

Generally speaking, 5 business days from ,art approval is enough to do most orders. We rarely exceed 7 business days. Special process effects and large orders may need more time due to our current work load. Contact sales to schedule your order.

Do I have to provide my own art?

No, we have at least 3 artist in house most of the time and a handful of freelance artist at your disposal. Depending on the job the artist will establish a per hour fee or a flat fee. Depending on the size of the order or your budget we may throw in the art. This is purely dependent on the workload at the time.

Do I provide garments for printing or does Airship?

We are a dealer for most brands. We provide the garment to ensure quality and to prevent our machines from being fowled by inferior materials. If you have a custom garment that you need us to print- please contact us and be prepared to provide a sample for us to test.

What quality parameters can I expect from Airship?

Please refer to the downloadable .pdf file on the resources page called “Terms”.

Do you print stickers. banners, ect?

Yup! We print loads of different items. Feel free to ask- there is simply too much information to include on this faq page.

I’m a designer submitting a design to be screen printed. are there any tips I need to know?

Funny you should ask.
1. Whenever possible, create your art in vector format in Adobe Illustrator or a comparable program. Corel is not very comparable but we will try to work with these files.
2. If you have text in your image, embed the font or “create outlines” don't forget to hit expand. In AI Create outlines is under “TYPE” and expand is under “OBJECT”.
3. Create your image larger than it needs to be. If your lines change size when you change the size of the art, you forgot to “EXPAND”
4. Check your spelling. In AI you can do this under “EDIT”.
5. Compress your file if you are e-mailing it. On a Mac right click or hold down “Control” and click on the file then select “Compress” from the drop down menu. Or send your file through an ftp site like yousendit.
6. include a screen shot so that we are sure all your elements made it over and that your fonts are correct. On Mac you can do this by holding down the command, shift, and the number 4 key together. Pull the target across your image and a screen shot will appear on your desktop. You should be able to simply drag it into your e-mail on into instant messenger to send.
7. Check your spelling again.

Can you match PMS colors?

Yes, though through the software developed to do so, it is industry standard to vary up or down 1 pantone color.

Is the screen printing process harmful to the environment?

Mostly, No. We have been working with QCM inks during their Development of green inks. They have had pthalate free inks for over a decade. All the other ink companies have only recently begun to provide these child/earth safe inks. They are all doing it well so we have many options. Water based inks are deceptively less earth friendly. Mold and fungus grow in water so the inks have to contain chemicals like Urea to stay fresh. The content of this is minimal and is deemed safe for the consumer. The risk of exposure to these chemicals is primarily during the printing process. Everything that goes down our drain is filtered and deemed safe for water treatment. In fact, when our emulsion drain off arrives at the water treatment plant it encourages enzyme growth promoting a healthy treatment facility! Those enzymes love eating this stuff! The most volatile part of printing is the shirts themselves. The shirts we supply from our various suppliers are all rated as emitting a safe amount of formaldehyde. In order for a garment to be “pre-shrunk” it is treated with formaldehyde or “sizing” to stabilize the fabric from shrinking. We are not comfortable with the safest amount of formaldehyde since we are a family owned company and our child a friends are often here in the plant. Airship is equipped with substantial air movement and circulation equipment to keep ourselves and you safe. Organic shirts are not supposed to contain sizing chemicals so they will often shrink after washing. Keep this in mind when selecting your size. Other forms of printing we are capable of doing require solvent inks which are harmful to just about anything. We avoid these jobs but we do have the proper equipment and training to produce these items if needed. Increasingly, traditional solvents are being replaced by soy based products. We are currently testing a few of these soy products are happy to say they are terrific.

Are you the same Airship Printing that I saw in a ten foot wide store front a few years ago?

Yup, We grew fast. We have relocated a few times since 2005 and added more staff. We could not have done it with out our customers and we thank everyone who decided to keep their business in the US and in Colorado!

I have a non-profit, can you donate shirts?

Non-profits make up a substantial part of our business since t-shirts and banners are such key components for establishing your non-profits identity. We do what we can when we have the budget but it almost never amounts to a free job. In order to off-set a sizable donation we have to ask our employees and or friends to donate their time to help us print and people are getting tired of working for beer and pizza. We will defiantly figure out a way for you to have the best product printed at the best price. But we have bills too.

Is the screen printing you do similar to the screen printing I learned in art class?

Only in the way that a go-cart is similar to a semi-truck. Some of the principles are similar- but almost nothing is the same. in fact only about one job a day is printed on our manual press. Everything else is printed on an M&R automatic press. Even our posters are printed on a Filbar automatic.

How long have you been printing?

Airship has been in business since about 2005. John Magee, Owner of Airship opened his first shop in 1998 and has been printing since the early 90’s. Everyone else on staff has been printing for at least 3 years and usually more.

What type of clients do you usually print for?

There really is no usual client. We print jobs for anybody from your family reunion to large national brands as well as companies outside of the US. We would give examples- but some of our biggest clients do not allow us to display their samples to protect their brand identity. Additionally we print for marketing agencies, promotional products companies, as well as other screen printers.

I have a small order, should I go elsewhere?

Most likely not. We will not forget our roots when a 6 piece job helped pay the bills. Additionally, the smaller shop you go to will likely just outsource it to us anyway. I can’t count how many times in the early days when we were a small shop that I would receive a job from another shop that I had quoted a price for just the day before. In those days- people were worried that we were too small to produce a quality item for them and would take the job to another shop that already outsourced their work to us. The simple fact is that most of the businesses that advertise screen printing are just a middle man. You save by going directly through us or one of our affiliates. Anything that we do not do in house- we produce through one of our partner businesses that we supply for. If we can not get you the best price for a quality product - we will refer you to someone who can.

Dude, I can't believe you read all that!