Water-Based or Plastisol: Which Screen Printing Ink is Best for You?

 

You’ve got the perfect vision for custom tees for your youth group, church or faith-based organization. But now, you’ve hit a crossroads—water-based or plastisol ink? If this is your first time ordering tees, you might feel baffled as to the difference between them. Don’t sweat it! We’re about to break it down so you can pick the ultimate ink for your awesome design.

What is plastisol ink?

Plastisol ink, also known as the traditional ink, has been the popular choice since the 60’s and 70’s. It’s a plastic ink that lays directly on top of the fabric. To get all technical, it’s made up of PVC resin, which forms the body and structure of the ink, and a plasticizer, a liquid component that keeps the ink flexible and in a liquid state until cured (whew…deep breaths for that looong explanation). To properly cure plastisol ink, temperatures must reach between 270ºF and 330ºF. When you see a custom design screen printed on top of a shirt, it’s most likely done by this method.

What is water-based ink?

Water-based ink—as the name implies—is made with water, and is generally considered to be the more eco-friendly choice. It works by dyeing the shirt itself instead of depositing ink on top. Unfortunately, we have to get technical again: water-based ink is made up of water as the solvent, pigments for color, and a binder, which is generally made from acrylic resins or hybrid blends of acrylic resin and polyurethanes, to help the pigment adhere to the garment (we’re really out of breath now). The ink prints by replacing the original color of the shirt and depositing the new ink in its place. Water-based inks change the color of the fabric of the shirt, whereas plastisol places dye on top.

So, let’s talk about what you need to know before choosing the best one for you.

Battle of the Inks: Water-Based Ink vs Plastisol

Round 1: Which one has colors that pop?

When it comes to the vibrancy of your shirt, both water-based and plastisol print differently. With plastisol, the ink sits on top of the shirt leaving a brighter outcome. With water-based printing, there are a variety of different shades since it dyes the fabric itself. Depending on the garment being printed on, the outcome can range from bright colors to a faded, toned-down version (which can be good for those vintage, distressed designs). This is especially true when printing on darker-colored garments since plastisol prints a white layer on top, creating a brighter white underbase for the colored ink to pop off of. Since water-based ink removes the dye of the fabric then lays down the white ink, the underbase will be closer to off-white, making the color printed afterward not as vibrant.

Winner: Plastisol! This ink isn’t just popping—it’s practically doing a mic drop. 

Round 2: Which one leaves the fabric feeling breathable and smooth for maximum comfort?

Because of the way water-based ink is printed, you can’t even feel the dye on the shirt. With plastisol, the dye is noticeably there because it adds a small layer on top of the shirt. When printing on a darker-colored shirt, this layer is even more noticeable since plastisol prints a white layer, called an underbase, before the full-color layer, leaving an even thicker print on top of the shirt. For this reason, plastisol ink feels much thicker than water-based ink in comparison and definitely not as breathable

Winner: Water-Based Ink! If softness and breathability for staying cool on a hot summer’s day were a competition, this ink just walked away with the gold medal.

Round 3: Which one will last through years of wear and tear?

Ah, the age-old question: which one lasts longer? If you’re picking a shirt design for tees you intend to use for a long time, you’re probably thinking: “Okay…which one is more durable?” 

Well, the good news is that the answer is both! Both inks are extremely durable due to the way they’re cured. Your shirt fabric will absorb the water-based inks, whereas plastisol is permanently bonded to the surface of your shirt. So, both designs will last as long as your shirt does! Here at Uth Stuph, we use t-shirts made of only top-quality materials that ensure longevity for your tees, regardless of the printing method you choose.

Winner: We’re calling this one a tie! Both inks are built to last, just like your faith and fashion sense.

Round 4: Which one has the best color-matching capabilities?

If having an exact color match is important to you (for example – if you’re ordering shirts for your organization’s sports team or if branding consistency for your organization is a must), plastisol ink has better color accuracy. With water-based inks, results may vary due to many different factors, such as the color of your shirt, press conditions, dye migration and temperature control. Because plastisol ink bonds to the top of your shirt, as we learned earlier, their colors are more dependable and exact. 

Winner: If exact shades matter, plastisol is your MVP.

Round 5: Which one is easier on my pockets?

If staying under budget is a concern for you, costs matter. Although we offer affordable prices and always work with you to find the best deals available, plastisol is usually the cheaper option. And due to the high yield the ink gives, you get more “bang for your buck.” Because plastisol can also be used on a wider variety of materials than water-based ink, you have more options of shirt blends that you can choose from that will work within your budget.   

Winner: Plastisol is a smoking deal!

Round 6: Which one has the quickest turnaround time?

For the most part, water-based inks can be trickier to work with. Due to the number of challenges that can arise with water-based printing, it doesn’t have the quick turnaround time that traditional ink does. Plastisol ink is pretty straightforward, though, as you literally take it from the bucket, to the screen, and then onto the shirt—easy as that.

Winner: Plastisol wins this one. No waiting around—this ink is all about speed, efficiency and no drama.

Round 7: Which one is more versatile?

If you’re looking to customize more than just t-shirts, like hoodies and hats, plastisol ink has greater versatility. You can practically print plastisol on anything (…ahem…not that you should), including cotton, blends, performance fabric, polyester and synthetic fabrics. However, water-based inks tend to perform better on fabrics that are 100% cotton. You can run into complications if you use water-based inks on blended fabrics, since the ink will absorb differently on the synthetic parts than it will on the cotton portions. 

Winner: Plastisol races to the finish line!

Luckily, it doesn’t matter which screen-printing method you pick. Whether it’s plastisol ink or water-based ink, Uth Stuph has got you covered! If you need help deciding which one is best for you, give us a call at 800-242-9166 or get a quote now. We’d love to show you how simple it is to get awesome custom shirts made, regardless of the ink you choose!