At Rusthead our main printing method is Screen Printing. We Strictly print with Water Based Inks.
Water-based inks are premium inks and offer a higher level of quality, comfort, and craftsmanship more than Plastisol printing methods. They’re the choice of high-end apparel brands that value both design integrity and sustainability. This is the only printing method that we offer he at rusthead.
Water-based screen printing is an eco-conscious alternative to traditional plastisol printing because it uses water as the main solvent instead of petroleum based chemicals. This simple difference makes a big environmental impact.
There is a lot work involved with set up in Screen Printing for low quantity or high color prints please refer to Digital Printing.
We offer Three types of Printing
High Solid Acrylic
Soft Base
Discharge
The Process
Your artwork is separated by color and prepared for printing. Each color will have its own individual screen.
A fine mesh screen is coated with a light-sensitive emulsion. The design is then exposed onto the screen using light, hardening the emulsion around the artwork. The areas that weren’t exposed wash away, leaving a stencil of your design.
Each screen is aligned on the printing press so that the colors line up perfectly. The garment is then placed securely on a platen to ensure accurate placement.
Ink is pushed through the open areas of the screen using a squeegee, transferring the design onto the fabric. This step is repeated for each color layer in the design.
After printing, the garments go through a high-temperature dryer that cures the ink bonding it permanently to the fabric for durability and wash resistance.
Every garment is inspected for color accuracy, alignment, and print quality before it’s folded, packaged, and ready to go.
High Solid Acryilic Printing
HSA (High-Solid Acrylic) water-based printing is an advanced, eco-friendly screen-printing process that combines the soft feel of traditional water-based inks with the vibrant color and opacity of plastisol. These inks use a high concentration of acrylic solids suspended in water, allowing them to sit slightly on top of the fabric while still soaking in enough to maintain a smooth, breathable finish. This is the default way we Screen Print since it is ideal for both light and dark garments.
Why HSA Water-Based Printing?
Soft & Comfortable: The print feels smooth and lightweight, never heavy or rubbery.
Vibrant Colors: HSA inks produce rich, bold tones that stand out on nearly any fabric.
Eco-Friendly: Made with water and acrylic binders instead of PVC or phthalates, making it safer for people and the planet.
Durable: Once cured, the ink bonds firmly to the fibers for long-lasting prints that resist cracking or fading.
Versatile: Works beautifully on cotton blends and darker garments, expanding what’s possible with water-based printing.
HSA water-based printing is perfect for premium apparel lines, retail-quality merch, and brands focused on sustainability and comfort. It delivers the professional look of high-end fashion prints while maintaining Rusthead’s commitment to environmentally responsible production.
Soft Base Printing
These inks soak into the fabric rather than sitting on top, creating a soft, breathable feel that becomes part of the garment itself. The result is a print that’s smooth to the touch, long-lasting, and perfect for achieving a vintage or high-end look. These inks have to be darker than the shirt. So ideally these are on light colored shirts
Why Choose Soft Based Printing?
Soft Feel: The ink blends with the fibers for a lightweight finish that doesn’t crack or peel.
Eco-Friendly: Made without harsh chemicals, water-based inks are safer for both people and the planet.
Vibrant, Natural Look: Colors appear rich yet subtle, ideal for fashion-forward or boutique-style designs.
Durability: With proper care, prints stay vibrant through years of wear and washing.
Only works on White or very Light colored shirt Such as Gildan 5000, BellaCanvas 3001, and Comfort Color 1717. It’s a favorite for brands that value quality, comfort, and sustainability — from retail lines to event merch.
Discharge Screen Printing
Discharge printing is a specialized water-based screen-printing technique that removes the dye from a garment’s fabric and replaces it with new color. Instead of laying ink on top, discharge ink chemically “bleaches” the original dye in the cotton fibers, leaving behind a soft, breathable print that feels exactly like the fabric itself.
The result is a vintage-style, no-feel print with rich color and incredible comfort — perfect for premium apparel where softness and detail matter.
Why Discharge Printing?
Ultra-Soft Feel: The design becomes part of the fabric there’s no raised ink or heavy texture.
Vibrant, Natural Colors: Produces detailed, crisp prints with a unique, worn-in look.
Breathable & Comfortable: Since there’s no ink buildup, the shirt stays cool and flexible.
Discharge printing is ideal for premium apparel, vintage-style graphics, or brands that value both comfort and sustainability. Each print has a slightly unique character, giving your design a handcrafted, high-quality look that stands out. Please consult a Rusthead member to ensure that We are able to discharge your job.
