Screen Printing with Plastisol Inks vs. Water-Based Inks: Which Ink and Printing Method is better for Your T-shirt Designs?

jason on January 1, 1970, 12:00 AM

Screen printing is one of the most popular methods for printing designs onto t-shirts and other apparel. However, not all screen printing inks are created equal. Two of the most widely used types of inks in the industry are plastisol inks and water-based inks. Each of these ink types has its own set of characteristics, advantages, and challenges, making them suited for different applications and end-user preferences.

In this blog post, we'll break down the key differences between screen printing with plastisol inks and water-based inks, helping you understand which option might be best for your next t-shirt printing project.

What are Plastisol Inks?

Plastisol ink is the most commonly used type of ink in screen printing. It is a PVC-based ink that is thick, opaque, and usually has a high viscosity. Plastisol inks do not dry until they are cured by heat, which makes them ideal for screen printing applications. Because plastisol inks remain wet until cured, they are incredibly versatile for printing on a variety of fabric types and colors.

Key Characteristics of Plastisol Inks:

Opacity: Plastisol inks are highly opaque, which means they provide strong coverage, even on dark-colored fabrics. This opacity allows for vibrant colors and crisp details, even on challenging surfaces.
Durability: Plastisol prints are highly durable and resistant to fading, cracking, and washing out over time. This makes them ideal for products that will undergo heavy use and frequent washing.
Curing Process: Plastisol inks need to be cured in a heat press or conveyor dryer at a specific temperature (typically 320°F / 160°C) for them to bond with the fabric.
Feel: Plastisol ink sits on top of the fabric, creating a more noticeable texture that can feel slightly raised or "rubbery" to the touch.

What are Water-Based Inks?

Water-based inks, as the name implies, use water as a solvent to carry the pigments. These inks are known for their eco-friendly properties and are preferred by many printers who are looking to minimize the environmental impact of their work. Water-based inks are designed to soak into the fabric, creating a softer, more breathable print.

Key Characteristics of Water-Based Inks:

Transparency: Water-based inks are generally more transparent than plastisol, and while they can achieve vibrant colors, they often require a white base or multiple layers to create opacity on dark fabrics.
Soft Feel: One of the most appealing features of water-based inks is their soft feel on the fabric. Since the ink absorbs into the fibers rather than sitting on top, it creates a smoother, less noticeable print. This results in a “barely-there” feel, which is ideal for those looking for a more subtle finish.
Breathability: Because the ink permeates the fabric, water-based prints are often more breathable, making them ideal for applications in performance apparel or for customers who prefer a lightweight, comfortable print.
Environmental Impact: Water-based inks are typically more eco-friendly than plastisol inks. They have fewer harmful chemicals and are free from PVC, phthalates, and other toxic substances that are present in plastisol inks. Water-based inks are also biodegradable, which makes them a more sustainable option for environmentally conscious consumers.

Comparison: Plastisol vs. Water-Based Inks

1. Feel and Texture

Plastisol Inks: Since plastisol inks sit on top of the fabric, the print tends to have a more noticeable texture. The print can feel thick or rubbery to the touch, which some people find desirable for designs that need bold, tactile elements. However, this can be a downside for customers looking for a softer print.
Water-Based Inks: Water-based inks absorb into the fabric, creating a soft, smooth feel that’s almost like part of the garment. This is often seen as a premium quality print, as it gives the shirt a more "vintage" or "worn-in" look and feel.

2. Durability

Plastisol Inks: The durability of plastisol inks is unmatched. Once cured, plastisol prints are extremely resistant to fading, cracking, and washing out. They tend to last a long time, even with frequent use and washing.
Water-Based Inks: While water-based inks are durable, they tend to be more susceptible to fading and wear over time, particularly when printed on dark garments. However, they have the advantage of being softer, and they won't crack or peel in the way plastisol prints sometimes can.

3. Opacity and Coverage

Plastisol Inks: Plastisol inks are thick and opaque, which means they can cover a variety of fabric colors with ease. This is particularly advantageous when printing on dark or black shirts, as plastisol’s opacity ensures the design pops.
Water-Based Inks: Water-based inks are more transparent and generally less opaque, which can make them more difficult to use on dark-colored fabrics without applying multiple layers or a white underbase. However, this transparency can be used to create lighter, more subtle designs.

4. Environmental Impact

Plastisol Inks: Plastisol inks contain PVC, which is a synthetic material that is not biodegradable. Additionally, they require the use of solvents during cleanup (although some eco-friendly plastisol inks are available). This makes plastisol a less environmentally friendly option compared to water-based inks.
Water-Based Inks: Water-based inks are considered more environmentally friendly, as they are free from PVC, phthalates, and other toxic chemicals. They also clean up easily with water, reducing the need for harsh solvents and contributing to a more sustainable printing process.

5. Printing Process

Plastisol Inks: Plastisol inks are easy to work with and are suitable for both beginner and advanced printers. They can be used for high-volume production and on a wide range of fabric types. However, they require a curing process at higher temperatures, which can slow down production in some cases.
Water-Based Inks: Water-based inks can be more challenging to work with, particularly when printing on dark fabrics. They have a lower viscosity, so they tend to be thinner and require more careful control during the printing process. Additionally, water-based inks need to be dried properly to avoid smudging or washing out, which can increase production time.

6. Application Use Cases

Plastisol Inks: Plastisol inks are perfect for bold, vibrant designs that need to be durable and highly visible. They’re commonly used for sportswear, promotional items, and any product that requires a long-lasting print. They’re also preferred for printing on synthetic fabrics like polyester.
Water-Based Inks: Water-based inks are ideal for customers seeking a soft, eco-friendly print with a more vintage or subtle feel. They’re often used for premium or fashion-forward brands, particularly when the feel and comfort of the garment are paramount. Water-based inks are also a good choice for organic or sustainable clothing lines.

Conclusion: Which Ink Should You Choose?

When deciding between plastisol and water-based inks for your screen printing project, it ultimately depends on the type of design, fabric, and end-use you’re targeting.

Choose Plastisol Inks if you need vibrant, opaque prints that will stand up to wear and tear over time. Plastisol inks are a great choice for designs that require durability, sharpness, and strong color visibility, particularly on dark fabrics.
Choose Water-Based Inks if you’re looking for a soft, breathable print with an eco-friendly edge. Water-based inks are perfect for designs that require a vintage feel, a soft hand, and are intended for lighter fabrics or premium lines.

Both ink types have their advantages, and understanding the unique properties of each will help you make the best decision for your screen printing needs.