What is Halftone Dots?
Technical definition, shop floor implications, and pricing strategies for commercial apparel decorators.
A pattern of microscopic ink dots of varying size and spacing that simulates continuous-tone gradients, photorealistic shadows, and color blends using solid spot color inks.
Deep Dive & Practical Application
Because screen printing is a binary process (ink either passes through a mesh open stencil or is blocked), gradients and photographic art cannot be printed with varying ink densities.
Raster Image Processors (RIP) convert smooth digital tone gradients into mathematical grids of tiny halftone dots (measured in Lines Per Inch or LPI, typically 45–65 LPI for apparel). Larger dots clustered together create dark shadow tones, while smaller dots spaced apart produce light highlights.
Dot shape (elliptical, round, or stochastic) and screen angle (e.g. 22.5° or 61°) must be calibrated to prevent optical Moiré interference patterns with the woven mesh threads.
Shop Floor & Profitability Impact
High-LPI halftones require high-tension screens (230+ mesh) and precise exposure calibration. Blown-out highlight dots or dot gain in the darkroom will ruin photographic realism on finished shirts.
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