In this new episode of Deep Dive with Colin, we’re diving into oversized printing with a Christmas twist! We’ll walk you through the highs, lows, and lessons learned while printing a Christmas-themed shirt. Whether you're gearing up for the holidays or just want to try something bold, this deep dive will help you tackle oversized prints with confidence.
WHY OVERSIZED PRINTS ARE AWESOME
Oversized prints grab attention and give designs room to shine. For this project, we wanted the cozy look of a Christmas sweater with a modern twist. Adding puff ink gave the print texture, making it pop off the shirt. The end result? A design that’s fun, festive, and perfect for the holidays.
RELATED: TOOLS NEEDED FOR OVERSIZED PRINTS
GETTING THE RIGHT EQUIPMENT
To make this design work, we used the Riley Hopkins 360 press, which paired perfectly with an oversized platen. The platen allowed enough space for the 13-inch-wide by 17-inch-tall design while maintaining good support for the shirt. High-tension 23x31 screens were key to keeping the registration tight across the tall print area. We used a 16-inch squeegee to spread the ink evenly without stretching or distorting the mesh.
MAKING THE DESIGN WORK
We started with FN puff ink for the white underbase, adding 10% to give the print a soft, raised texture. The mesh made a difference too. A 156-mesh screen worked perfectly for the puff ink, while a 230-mesh screen handled the details in the green and red colors.
One tricky part was flashing such a big print. If the platen isn’t centered under the flash dryer, parts of the print won’t heat evenly. This can cause problems like ink sticking to the screen or lifting off. Double-checking the temperature and position kept things running smoothly.
RELATED: TAKE YOUR PRINTS TO THE THIRD DIMENSIONS
WORKING WITH PIXEL ART
Pixel art was key to nailing the "ugly sweater" look. It’s a great way to add charm and character to your designs, but it can be tricky if you’re new to it. To save time, we started with a pre-made pattern for the snowflakes and reindeer. Templates like this make it easy to get a clean design without starting from scratch.
For the text, we kept the style simple and blocky to fit the pixel theme. The biggest challenge was creating diagonal lines. Pixel art uses straight lines or sharp angles, so anything at 30 or 45 degrees takes patience to make look smooth. Testing the design on paper first helped us catch any awkward spots before moving to the screen.
Once the design was ready, registration became the next big challenge. Oversized pixel art requires precise alignment, especially when layering colors. Using high-tension screens and adjusting the choke on the underbase helped keep the design sharp.
WHAT WE LEARNED
We made a few mistakes along the way, but they turned into valuable lessons. First, our 0.75-point choke on the white underbase was too aggressive. It left a little too much overlap, and a standard 0.5-point choke would’ve worked better. Second, we realized how important it is to plan for your equipment’s limits. The design pushed our platen to the edge, which made maneuvering the squeegee tricky. Finally, even experienced printers can run into lifting issues. Taking the time to check flashing temperatures evenly could’ve saved us some frustration.
RELATED: GUIDE TO CREATING AN UNDERBASE IN ADOBE ILLUSTRATOR
THE FINAL RESULT
Despite a few hiccups, the print turned out great! The puff ink gave the design a raised texture that feels like a sweater. The bold green and red colors popped against the white underbase, and the pixel art details made it fun and festive. The oversized size made the shirt a statement piece that’s perfect for holiday wear.