Welcome back to another Deep Dive with Colin. We're getting hands-on with discharge printing—a technique that’s both rewarding and a bit tricky, but with the right knowledge, you can create stunning, soft prints with that vintage feel. Let's break down the process, focusing on using Aquarius discharge base and discharge activator, particularly zinc formaldehyde sulfoxylate (ZFS).
WHAT IS DISCHARGE PRINTING?
Discharge printing is a method where the dye in a fabric is removed and replaced with a new color, or simply left in its natural state. It’s particularly popular for achieving soft, higquality prints on dark garments. The key player here is the h-discharge activator, which works its magic to neutralize the fabric's dye under heat, revealing a natural or dyed color.
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PREPPING YOUR DISCHARGE INK
First things first: always mix your discharge ink accurately using a scale, as the activator is added by percentage. For today's demo, Colin uses 100g of discharge clear base and adds 6g of discharge activator—aiming for a 6% mixture, which is typically a good starting point.
Pro Tip: Stir your ink thoroughly to prevent evaporation issues, and always let it sit for 5-15 minutes after mixing. This resting period allows the activator to fully dissolve, ensuring you avoid any streaky prints.
SETTING UP FOR SUCCESS
While your ink is settling, prepare your screen. Colin recommends a 158 thin thread screen for this process. The thin thread allows more ink to flow through with less pressure, making it easier to print and clear out dried ink.
When it comes to squeegees, a 65/90/65 triple durometer squeegee is ideal for good ink coverage, but if you need more control, try a 70 durometer squeegee.
PRINTING AND CURING
Next, it’s time to print! Colin demonstrates on a 100% cotton shirt with a good discharge rating. Remember, each fabric reacts differently, so always check with your distributor for the best results. After printing, flash the design to initiate the discharge process.
Important: Ventilation is key here. During discharge, formaldehyde is released as the fabric’s dye breaks down. Use a dryer with proper air movement, like the Aeolus by BBC, to ensure safe and effective curing. Smaller setups can benefit from adding Warp Drive to your ink, which ensures a full cure even without a high-powered dryer.
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TROUBLESHOOTING AND FINAL TOUCHES
If your ink doesn’t fully discharge, it could be due to undissolved activator or other factors. Let the ink fully discharge through the dryer before diagnosing any issues. For water-based inks that dry quickly in the screen, keep a spray bottle of distilled water handy to refresh the ink as you work.
Lastly, remember that discharge printing, like all techniques, comes with its nuances. Whether it’s controlling the amount of pigment or ensuring proper ventilation, each step is crucial for achieving a crisp, vibrant print.
SAFETY FIRST
Discharge printing involves chemicals that can cause allergic reactions, particularly the sulfur in the activator. If you're sensitive, take necessary precautions—gloves, masks, and proper ventilation should be part of your setup.
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FINAL THOUGHTS
Discharge printing is a fantastic way to create unique, high-quality prints, especially on dark fabrics. While it has its challenges, like managing ink drying or ensuring even discharge, the results are worth it. Practice, test, and tweak your process, and you’ll master this technique in no time.
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