Screen Printing for Thick Ink Application
Screen printing thick ink layers presents significant technical challenges in maintaining print quality while delivering sufficient ink volume. Current industrial processes struggle to achieve consistent deposits above 100μm thickness, with issues of mesh marking, irregular coverage, and edge definition becoming pronounced as ink volume increases. These challenges are particularly evident in applications like automotive displays and electronics, where precise thick-film deposition is critical.
The fundamental challenge lies in balancing ink transfer volume through the mesh while maintaining print definition and preventing both blocking and bleeding effects.
This page brings together solutions from recent research—including 3D structured screens with variable bridge thickness, parallelogram-patterned mesh designs, advanced mesh architectures with selective thread removal, and metal mesh screens with customized ink penetration holes. These and other approaches focus on achieving consistent thick-film deposits while maintaining print quality and production efficiency.
1. Screen Printing Ink for Thermoplastic Resin Substrates with High-Boiling Solvent and Thermoplastic Polymer
Dai Nippon Printing Co., Ltd., TEIKOKU PRINTING INKS MFG CO LTD, 2017
High-quality and high-precision screen printing ink for thermoplastic resin substrates that can produce printed products with compatibility for molding processes. The ink allows screen printing fine dots, lines, and large monochromatic areas in one step. The ink has solvent with a boiling point of 170°C or higher, a thermoplastic polymer with Tg 20-95°C, and viscosity 5-180 Pa·s. This provides flexibility and durability for molding while preventing film cracking and leaking. The ink also contains dispersed pigments with particle size 35 µm or less. The ink composition enables high-resolution screen printing with low defects, like pinholes, for thermoplastic substrates like automotive interiors, displays, electronics, and molded products.
2. 3D Structured Screen with Variable Bridge Thickness for Enhanced Ink Transfer in Screen Printing
SPG Printing Company, SPG PRINTS BV, 2016
A screen printing technique using a new type of screen that allows printing with larger amounts of ink and high resolution. The screen has a 3D structure with peaks and valleys on the printing side. The peaks are formed by thicker bridge portions between the mesh openings compared to the valleys at the intersections. This 3D structure improves ink transfer and sharpness compared to traditional flat screens. The 3D screen can be made by electroforming metal mesh.
3. Metal Mesh Screen Structure with Pattern Grooves and Variable Ink Penetration Holes for Printing
Canghe Precision Manufacturing Co., Ltd., BRAVE C&H SUPPLY CO LTD, Canghe Co., Ltd., 2015
Integrally formed screen structure for printing with high toughness and strength. The screen has a mesh fabric made from a metal plate instead of interlaced threads. The mesh has pattern grooves on the printing side and ink penetration holes on the scraping side. The grooves match the patterns being printed. The holes have inconsistent shapes and sizes. This allows customized ink penetration to match the pattern shapes. The groove depth is less than the mesh height and pattern height. This prevents ink leakage. The holes are larger than the grooves. This allows ink to pass through while preventing clogging. The pattern grooves and ink holes are formed directly in the metal mesh, eliminating the need for interlaced threads. This provides a more durable, high-strength screen plate for printing.
4. Screen Printing Apparatus with Circular Base and Resilient Annular Member for Wrinkle-Free Article Retention
HARRINGTON ROBERT J, 1991
Screen printing system and method to prevent distortion and improve quality of printed images, especially on thick or multiple layered articles like jackets. The system uses a circular base with a resilient annular member to securely hold the article without wrinkles. The article is then printed by passing ink through a parallel screen above it. This prevents distortion by avoiding wrinkles on the printed area. The annular member ensures the article is evenly held flat against the base.
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