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Why Screen Printing Needs Vectors
Screen printing works by pushing ink through a mesh screen. Each color requires its own screen. Vector files are essential because they allow automatic color separation – a process that would be nearly impossible with raster images.
Unlike digital printing that can print any color directly, screen printing works best with 2-6 colors, sometimes up to 10+. Your vector file needs to be structured so the print shop can easily separate it into individual color layers.
1. Color Separation Requirements
What is Color Separation?
Color separation is breaking your design into individual color layers. Each layer becomes one screen and one ink color on the shirt.
Example:
Your design has red, white, and black. That's 3 colors = 3 screens needed. Print shop will create one screen for red ink, one for white, one for black.
Spot Color vs Process Color
Two approaches to t-shirt printing color:
Spot Color (Simpler)
Each color is a solid ink color. Limited to 6-8 colors usually. Great for logos and simple designs. Use Pantone color numbers.
Process Color (Complex)
Like color printing – uses CMYK to create any color through dot patterns. Can print photos but requires more screens (4+).
How to Prepare for Color Separation:
Use solid colors only
No gradients, no transparency – solid fills only
Limit color count
Fewer colors = cheaper printing. 1-4 colors is ideal for cost
Put each color on its own layer
Layer 1: Red, Layer 2: Blue, Layer 3: Yellow. Makes separation obvious
Use Pantone colors if possible
Pantone color numbers ensure exact ink matching (optional but professional)
2. Design Sizing & Placement
Standard T-Shirt Print Areas
Front Chest:
Typical: 6" x 6" to 8" x 8" | Height from bottom of shirt collar: 2-3"
Full Front:
Large design: 10" x 12" to 13" x 14" | Positioned on upper-middle chest
Back Print:
Typical: 10" x 12" | Centered on back
Sleeve Print:
Small: 2" x 2" to 3" x 3" | Positioned on upper arm
Important: Ask Your Print Shop First
Exact sizing and placement rules vary by t-shirt brand and print shop. Always ask for their specific requirements before finalizing your design.
3. Technical Requirements
File Format
Submit .AI (Adobe Illustrator) or .EPS. PDF is acceptable backup.
Color Mode: CMYK
Convert to CMYK in Adobe Illustrator (File → Document Color Mode → CMYK). NOT RGB.
Convert Fonts to Outlines
Select all text → Type → Create Outlines. Print shop might not have your custom fonts.
Flatten the Design
Remove transparency, expand strokes, ensure everything is merged and ready for printing.
Set Artboard Size
Artboard dimensions should match print area. 6x6" for chest print, 10x12" for full front, etc.
4. Common T-Shirt Printing Problems
Problem: "Colors Don't Match the Original"
You specified blue on screen, but it prints purple. This is RGB vs CMYK mismatch.
✓ Solution: Design in CMYK from start. Use print color swatches to specify exact colors.
Problem: "Gaps Between Colors"
Different color areas don't line up perfectly (called "registration issues").
✓ Solution: Overlap colors slightly (1/16" overlap), or ask print shop about "registration tolerance."
Problem: "Text Is Too Small"
Small text becomes unreadable when printed, or ink fills in details.
✓ Solution: Minimum text size 8pt for sans-serif fonts. Test at actual print size first.
Problem: "Design Looks Fuzzy"
Raster image was embedded instead of vector artwork.
✓ Solution: Use vector shapes and text only. No embedded photos or raster images.
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