What mesh count means
Mesh count is the number of threads per inch in the screen fabric. Lower counts have bigger openings that lay down more ink, which suits bold graphics, underbases and thick specialty inks. Higher counts have smaller openings that hold fine detail and deposit a thinner ink layer, which suits halftones and process printing.
Thread diameter matters too. Two 156 meshes with different thread thicknesses won't print the same, so stick to one supplier's mesh when you're dialing in a process.
Mesh count by job
- White underbase on dark garments: 110–156, depending on how opaque your white is and how much hand you can accept.
- General spot-color plastisol: 156 is the workhorse most shops keep the most of.
- Water-based and discharge inks: often 156–200 so the ink doesn't dry in the screen.
- Halftones and fine lines: 200–230 for apparel, 305 for tight CMYK process work.
- Glitter, shimmer and puff: 86–110, because large particles need large openings.
Matching mesh to halftone LPI
A useful rule: mesh count should be about 4–5 times your halftone LPI. So 200 mesh holds up to about 45 LPI, and 305 mesh holds about 65 LPI. Go too fine for the mesh and the dots won't hold.