How'd They Do That; T-Shirts

The high-resolution digital image

is received and reviewed to make

sure it is good enough to print

(preferably 300 dpi at size).

A paper proof is printed. The paper

proof is calibrated to match the

colors the press can achieve and is

used for matching on press.

The image is color separated using

Photoshop. The layers are output on

a high-end image setter, resulting in

a clear transparency for each color.

Each color requires its own screen,

which is exposed to an intense

light in an exposure unit. A thin layer

of emulsion on the screen is

cured by the light.

The film is removed from the

screen and the unexposed areas

of the screen are washed out with

pressurized water.

Each screen is taken to the

press and precisely adjusted for

registration tolerance of 0.001”.

A white underbase is printed to

block out the T-shirt color.

The magenta layer is printed and

you can begin to see the image

develop.

Yellow comes next to add life to the

headdress.

With the cyan layer, flesh tones

come to life.

The final layer, black, completes the

image and adds depth.

The finished product is ready to

wear.