Different mesh counts are used for different applications in the screen printing process. What is mesh count? Well, mesh count is a measure of how many polyester threads (which used to be silk centuries ago, hence "screen printing") cross each other per square inch of screen. For example, a 110 mesh screen will have 110 threads crossing each other per square inch. The higher the mesh count, the finer the holes in the screen.
The first factor you should bear in mind when choosing a mesh size is the level of detail in the image. For example, your image has extremely high detail and a low-grid screen simply will not retain the detail. Thin lines or dots in the image will go right through the holes in the grid, giving you a poor representation of what your image should be.
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Another important factor to remember is the thickness of the ink itself. Thinner inks, such as water-based inks, usually require a higher mesh count. If too few mesh counts are used, then the thinner ink may spill out of the larger holes and soak your garment with more ink than expected. When the ink bleeds out, flooding your garment can make your image blurred. On the other hand, if you are trying to print with thicker ink (such as plastisol or white ink), you will need to consider a lower grid count. With too high a grid count you may experience problems with the ink not passing through the grid easily, which can lead to opacity and coverage problems.
You will notice that different companies have different sizes available. If the grid numbers are fairly close, for example, the difference between 155 and 156, 196 and 200 or 81 and 86, the difference will be negligible to the extent that it will have no effect on your final result. Because of the many variables involved in screen printing, we cannot tell you exactly which mesh sizes to use for which applications. However, we can provide you with a general overview of the sizes used for certain types of printing.
The two most standard mesh sizes are 110 and 156. 110 mesh will lay down a fairly thick layer of ink. This grid is ideal for block text letters and larger spot colour designs. It is also the recommended grid for your substrate as you only need to perform one pass, thus speeding up production. 156 mesh will leave a moderate amount of ink but will provide more detail capability for your image.
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With mesh counts below 110, they are most commonly used for speciality printing. The main areas where you will see a lower grid count used are for flash and shimmer inks. These inks are specially made with glitter in them to give the desired look. If your mesh count is too high, these flakes may get stuck in the mesh of the screen and not fall onto the shirt. Flash inks have larger, more visible flakes, while shimmer inks will have smaller particles to provide a more subtle look. 36 mesh size is ideal for flash inks, but you can go up to 64 mesh. For flash, 86 mesh is recommended.
Higher mesh size screens of 200 mesh and above are most commonly used for finer images and thinner inks. Graphics, plucking and water-based inks should be screen printed through this mesh size. Higher mesh counts help prevent thinner inks from spilling onto your substrate. These higher mesh counts can also help if you want your plastisol prints to have a softer feel. Printing thicker inks through finer mesh reduces the amount of ink deposited, resulting in a thinner 'plate' of ink. The result is a softer feeling print. While your plastisol print may feel softer, you may be sacrificing ink opacity by using a higher mesh count. If your design is intended to have very bright, vibrant colours, be aware of how much ink your screen allows you to print.
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