Mastering Screen Printing Emulsion: A Complete Guide

If you’re into screen printing, you probably know that screen printing emulsion is one of the most important components of the process. It’s the key to creating clean, sharp designs that transfer perfectly onto your materials. But with so many options out there, how do you choose the right emulsion and use it correctly? In this guide, we’ll break down everything you need to know about screen printing emulsion — from how it works to the best types to use — to help you get the best results.

Mastering Screen Printing Emulsion

What is Screen Printing Emulsion?

Screen printing emulsion is a light-sensitive liquid that’s applied to the mesh screen to create a stencil. When exposed to UV light, the emulsion hardens and creates a barrier, allowing ink to pass through the open areas of the stencil while blocking out the rest. This is what forms the design on your fabric, paper, or other surfaces.

Essentially, emulsion works like a photographic process. The areas of the screen that aren’t exposed to light remain soft and wash away, leaving behind the open mesh for your ink to pass through. The hardened areas create a clean edge, ensuring your design prints crisply and accurately.

Types of Screen Printing Emulsion

There are three main types of emulsion used in screen printing. The type you choose will depend on the type of ink you're using, your exposure setup, and your printing environment.

1. Diazo Emulsion

• Best for beginners

• Slower exposure time

• Budget-friendly and forgiving with exposure mistakes

• Works well with water-based and plastisol inks

  
  

  Diazo emulsions are easy to work with and great for those just starting out. Since they have a slower exposure time, they give you more room for error when exposing the screen.

2. Photopolymer Emulsion

• Fast exposure time

• High detail and sharp edges

• Best for large production runs

• Works well with plastisol inks

  
  

  Photopolymer emulsions are pre-sensitized, meaning they are ready to use straight from the container. They expose quickly under UV light, making them ideal for high-detail designs and fast production.

3. Dual-Cure Emulsion

• Versatile and durable

• Works with both plastisol and water-based inks

• High resistance to chemicals and wear

• Slower exposure time (but offers better detail)

  
  

  Dual-cure emulsions combine the best features of diazo and photopolymer emulsions. They’re more resistant to harsh inks and cleaning chemicals, making them a popular choice for professional screen printers.

How to Apply Screen Printing Emulsion

Applying emulsion correctly is key to getting a crisp and clean print. Here’s a step-by-step guide to help you do it right:

✅ Step 1: Prep the ScreenClean your screen thoroughly with a degreaser to remove any dirt, oils, or residue. A clean screen ensures the emulsion adheres properly.

✅ Step 2: Coat the ScreenUse a scoop coater to apply an even layer of emulsion on both sides of the screen. Start with the print side and then coat the squeegee side. A thin, even layer works best.

✅ Step 3: Dry the ScreenLet the emulsion-coated screen dry in a dark, dust-free environment. Dry it horizontally with the print side facing down to allow for even coating. Use a fan or dehumidifier if needed to speed up the process.

✅ Step 4: Expose the ScreenPlace your film positive onto the screen and expose it to UV light. The exposure time will depend on the type of emulsion and the strength of your light source. A proper exposure creates a strong stencil with sharp edges.

✅ Step 5: Wash Out the DesignAfter exposure, rinse the screen with cool water. The unexposed emulsion will wash away, leaving behind the design in the open mesh. Let the screen dry completely before printing.

Common Screen Printing Emulsion Problems and Fixes

👉 Underexposure: If the emulsion washes away too easily, it’s likely underexposed. Try increasing the exposure time or using a stronger light source.

👉 Overexposure: If the design details are not washing out or the emulsion feels too tough, you may have overexposed it. Lower the exposure time slightly.

👉 Pinholes and Bubbles: If you notice small holes in the stencil, your screen may not have been clean or the emulsion layer may have been too thin. Clean your screen properly and apply a more even coat.

👉 Emulsion Peeling Off: If the emulsion starts peeling after a few prints, the screen might not have been properly degreased or the emulsion may not have been fully cured during exposure.

Best Screen Printing Emulsions to Use

If you’re looking for high-quality emulsion that’s easy to work with and delivers professional results, check out the wide selection available at Screen Printing Emulsion. Screen Print Direct offers a variety of emulsions designed to handle different inks and production needs.

Some popular options include:

• Ecotex PWR Water-Resistant Emulsion – Ideal for water-based inks and high-detail prints.

• Ecotex LUX Photopolymer Emulsion – Fast-exposing and great for high-production runs.

• Ecotex DC Pink Dual-Cure Emulsion – Versatile, resistant to both plastisol and water-based inks.

Why Screen Printing Emulsion Matters

Using the right screen printing emulsion can make or break your printing project. A high-quality emulsion ensures that your stencil holds up during multiple prints, gives you crisp edges, and prevents ink bleed-through. Investing in the right emulsion saves you time and materials, and ultimately leads to better-quality prints.

Final Thoughts

Mastering screen printing emulsion takes a bit of practice, but once you get the hang of it, you’ll be able to produce professional-quality prints with ease. Whether you’re printing a small batch of custom shirts or running a full-scale production line, the right emulsion makes all the difference.

If you’re ready to take your screen printing to the next level, explore the top-rated emulsions available at Screen Printing Emulsion and find the perfect fit for your next project.