Question 1

How much ink does a standard screen printed t-shirt use?

Accepted Answer

A standard 12" × 12" graphic with 30% ink coverage printed through a 156 mesh screen typically uses between 0.025 and 0.04 ounces of plastisol ink per color. A gallon of plastisol ink (128 oz) can yield anywhere from 3,000 to 5,000 standard single-color impressions depending on screen mesh count and garment absorbency.

Question 2

How does screen mesh count affect ink consumption and cost?

Accepted Answer

Lower mesh counts (like 110 mesh) have larger open stencil openings, depositing up to 35%–50% more ink onto the fabric, which increases ink cost per print. Higher mesh counts (like 230 or 305 mesh) deposit a much thinner, softer ink layer, reducing ink consumption by up to 55% while capturing fine photographic halftone details.

Question 3

Why is white ink on dark shirts more expensive?

Accepted Answer

Dark garments require a solid white underbase layer followed by a flash cure unit before top spot colors can be applied. White underbase ink is formulated with heavy titanium dioxide pigments that require thicker deposits (110 or 156 mesh), effectively doubling the raw ink cost and adding an extra screen setup.

Question 4

How should print shops charge for screens and setup fees?

Accepted Answer

Industry standard practice is to charge between $15 and $30 per screen setup fee (covering film output, emulsion coating, darkroom exposure, and chemical reclaim). On runs under 72 units, screen setup fees are essential to maintain profit margins.

Question 5

How does The Print Life automate screen printing pricing?

Accepted Answer

The Print Life automatically builds your ink consumption, flash underbase requirements, color count multipliers, and screen setup fees into interactive pricing matrix tables. Your quotes automatically price jobs with guaranteed profit margins for a flat $49/mo.

Screen Printing Ink &
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2. Mesh & Consumable Costs

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How Screen Printing Ink Consumption Works

Screen Printing Ink & Mesh Cost Estimator