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The Battle of the Inks: Plastisol vs. Water-Based, Discharge, and More
Meta Description: Plastisol, water-based, or discharge ink? Learn which screen printing ink is best. Compare durability, cost, eco-friendliness, and softness in this simple guide.
1. Why Your Ink Choice Matters
Your screen printing ink decides how long your design stays bright, how soft it feels, and if it’s safe for Earth. Pick wrong, and shirts might crack, fade, or feel scratchy.
5 things to know:
- Durability: How many washes before fading?
- Softness: Stiff like cardboard or soft like pajamas?
- Eco-friendly: Does it hurt Earth?
- Cost: Cheap or pricey?
- Easy to use: Hard for beginners?
We’ll compare Plastisol, Water-Based, Discharge, and other inks.
2. Plastisol Ink: Strong but Stiff
What is Plastisol? A thick, plastic-like ink for bold designs.
Good Stuff:
- ✅ Bright on dark shirts (95/100 color score).
- ✅ Easy for new printers (won’t dry on screens).
- ✅ Cheap ($12.50 for 100 shirts).
Bad Stuff:
- ❌ Feels stiff (3.5/10 softness).
- ❌ Bad for Earth (has PVC plastic).
- ❌ Needs hot oven (320°F+ to dry).
Best for: Sports teams, cheap bulk orders, dark fabrics.
3. Water-Based Ink: Soft and Earth-Safe
What is Water-Based Ink? Thin ink that soaks into fabric. Feels like wearing air!
Good Stuff:
- ✅ Super soft (9/10 softness).
- ✅ Earth-friendly (low chemicals).
- ✅ Sharp details (tiny words look clear).
Bad Stuff:
- ❌ Fades faster (30-40 washes).
- ❌ Needs white underlayer on dark shirts (70/100 color score).
- ❌ Pricey ($18 for 100 shirts).
Best for: Baby clothes, eco-brands, light fabrics.
4. Discharge Ink: Soft + Bright on Dark Shirts
What is Discharge Ink? A mix of water-based ink and bleach-like powder. Removes shirt dye!
Good Stuff:
- ✅ Soft feel (7.5/10).
- ✅ Bright on dark shirts (85/100 color score).
- ✅ No plastic layer.
Bad Stuff:
- ❌ Works only on 100% cotton.
- ❌ Hard to use (needs perfect heat/humidity).
- ❌ Mid-price ($15.75 for 100 shirts).
Best for: Vintage-style shirts, cotton clothes.
5. Other Inks for Special Jobs
| Ink Type | Best For | Key Fact |
|---|---|---|
| UV-Curable | Posters, plastic items | Dries fast under UV light |
| High-Density | 3D logos (like jerseys) | Feels thick and bumpy |
| Eco-Solvent | Outdoor banners | No PVC, survives rain and sun |
6. Quick Ink Comparison
| Feature | Plastisol | Water-Based | Discharge |
|---|---|---|---|
| Durability | Best (50+ washes) | Good (30-40) | Better (40-50) |
| Softness | Stiff (3.5/10) | Softest (9/10) | Cozy (7.5/10) |
| Cost | $12.50 | $18.00 | $15.75 |
| Eco-Friendly | Bad (PVC) | Best (low chemicals) | Okay (zinc agent) |
7. Real-Life Examples
- Band Shirts: Use Plastisol for bright, tough logos.
- Eco Brands: Pick Water-Based for soft, Earth-safe shirts.
- Vintage Shops: Choose Discharge for retro cotton tees.
- Sports Teams: High-Density Plastisol for 3D numbers.
8. How to Pick Your Ink: Ask These 5 Questions
- Fabric type?
- Cotton: All inks work.
- Polyester: Only Plastisol or UV inks.
- Feel matters?
- Soft: Water-Based or Discharge.
- Bold: Plastisol.
- Budget?
- Cheap: Plastisol.
- Fancy: Water-Based.
- Earth-friendly?
- Yes: Water-Based or Eco-Solvent.
- How many shirts?
- Lots: Plastisol (fast + cheap).
- Few: Water-Based (premium feel).
9. Mistakes to Avoid
- Using Plastisol on Polyester: It cracks.
- Not drying enough: Ink washes off.
- Mixing inks wrong: Clogs screens.
- No gloves with Discharge ink: Hurts skin.
10. FAQs
Is Water-Based ink safe for babies?
Yes! Pick brands with Oeko-Tex certification.
Can I layer inks?
Yes (e.g., Plastisol over Discharge), but dry properly.
Which ink lasts longest?
Plastisol (50+ washes) > Discharge > Water-Based.
What’s popular in 2024?
Water-Based demand grew 18% (Grand View Research).
11. Conclusion: Who Wins?
- Plastisol: Best for cheap, bold prints.
- Water-Based: Best for soft, Earth-safe shirts.
- Discharge: Best for vintage cotton looks.
Test inks first! Ask brands for samples.
