4over png logo-2

Flexible Screen Printing for Signs

Screen printing is one of the core printing methods thought to have originated centuries ago in Asia to print on silk. You might hear it called silk screening. Today the screen material is most commonly polyester fabric or paper. Once a design is created, it is printed on a film to create a stencil for each color needed for the print. 

Screen Printing Components

The screen printing process involves six main components:

  • The frame
  • Stretched screen material
  • A photo emulsion
  • The image area
  • Ink
  • A squeegee


Typically made from aluminum, the frame holds the screen taut to produce a detailed printed image.

Stretched Screen

A mesh material, typically polyester, is stretched to fit tightly within the frame.


a layer of emulsion is applied to the screen after exposure; the areas that wash away are the printed area, while the remaining emulsion layer blocks ink from getting through the screen.

Image area

The exposed area of the photo emulsion that is washed away and will receive ink.


Many types of ink can be used in screen printing, making it suitable for printing on many different materials, from paper and plastics to textiles and garments.


Using pressure, the squeegee pushes the ink from the frame side (top) through the screen onto the material. Squeegees come in different hardness levels, measured in durometers, depending on the material being printed.

The Screen Printing Process

To create a screen print, the frame is mounted onto a flatbed or carousel press. Ink is pressed through the prepared and imaged screen to the material below using the squeegee.. Printing can be fully manual, semi-automated, or fully automated where pneumatic pressure or electric motors work the squeegee and assist in loading and unloading the material.

Screen Printing Colors

Screen printing can apply one or multiple colors and is compatible with 4-color process printing, using multiple screens to produce quality images. Applications like signs and t-shirts are often printed with one or two colors but can use even more based on the design. The two additional design considerations are related to the halftone mesh screens used in the process, in addition to fine lines and text. Designers should opt for thicker lines and larger font sizes due to the physical limitations of the screen mesh, which makes it harder to hold small dot sizes. The same limitation applies to halftone images (photos) which can typically be reproduced from 40-75% unless opting for a higher mesh count on the screen.

Other Considerations

Other production considerations are mostly related to the mesh screen and the angles to place each color separation when printing four or more colors. Fortunately, this is not a concern for your client but a part of the production steps managed by 4over. 


Coroplast is best described as plastic cardboard where layers of polypropylene are layered to make a fluted, cardboard-like material. Screen printing on coroplast allows a thick layer of ink to be applied with great adhesion strength, resulting in a highly durable image. These characteristics provide many benefits when screen printing coroplast signs. The inks used to screen print, much like the coroplast, hold up exceptionally well to environmental conditions like sun, heat, and moisture. These signs can be used and reused over an extended period and still look brand new.


Click here to see the new options available for screen-printed coroplast signage that is perfect for many outdoor uses, from events to real estate.



Keep Reading

4over Holiday Operations Schedule

All 4over locations are closed on the following public holidays in 2023: January 2 New Years Day May 29 Memorial Day July 3 Day Before Independence Day July 4 Independence Day September 4 Labor Day...

Read More

4over Pick-Up Hours

Pickup hours listed below are from Monday to Friday, excluding holidays. For a list of holidays, please view our Holiday Schedule. City Address Hours Arlington, TX 2112 West Division St. Arlington,...

Read More

Holiday Shopping Outlook 2022

How Inflation is Impacting Holiday Shopping Plans in 2022 Fall is right around the corner and the holiday season is fast approaching. In an unprecedented time with the highest rate of inflation in 40...

Read More

As one of North America’s largest trade-only printers and a trusted source for print fulfillment since 2001, 4over helps print, design, and other creative services resellers grow profitable businesses. We do this by offering a vast selection of quality print products at guaranteed trade-only prices. Our expansive e-commerce catalog includes everything from standard marketing collateral like business cards and brochures, to harder-to-find specialty, large format, and promotional products.

Our capabilities span gang run offset, digital, grand format, and promotional printing across six production facilities, staffed by experienced, committed operations teams. With locations across North America, state-of-the-art equipment such as powerful Incas and Scodix UV machines, and fast turnarounds, 4over offers our customers savings, selection, and scale. We serve large franchise printers, single print shops, print brokers, graphic designers, photographers, and every type of print reseller in between. Learn more at Trade.4over.com

1225 Los Angeles Street, Glendale, California 91204, United States

©2022 4OVER LLC, Terms and Conditions | Privacy Statement | CA Supply Chain Act