Graphics: Silkscreen vs Digital Print

At Protocase, we offer two ways to add graphics to your enclosures and parts: silkscreen and digital print. The primary purpose of both these methods is to achieve labeling – be it for things such as switchers, ports or connectors – on panels, parts and assembled enclosures. However, silkscreen or digital print can also be used to apply graphics such as your company’s logos or branding to your parts or enclosures.

Silkscreen and direct digital printing share some common traits. For one, both use an ink printing process. For silkscreening and digital printing, there are minimum font sizes you need to keep in mind. (Any powdercoat that has “Sandtex” in the name requires a minimum font size of 11 points).

Aside from that, silkscreen and digital print have distinct characteristics that make them unique. This blog post will go over both graphics processes, and offer some guidance as to which is most useful for certain scenarios.

Application Process

Digital printing is done by blending densities of cyan, magenta, yellow and black ink using industrial printers. As the UV printhead makes passes on the surface of the metal, the ink is then layered and instantly cured. This creates a linear texture that we call banding.

Silkscreen, on the other hand, involves burning graphics into a porous screen that is pretreated with photo emulsion. After burning in the graphics, we pressure wash the screen, which leaves an opening where the graphics were burned in. From there, the screen is laid onto the metal when the epoxy silkscreen ink is passed over. The ink goes through the screen and is applied directly to the metal surface.

With silkscreen, we currently stock 16 different colors. You can find them on our website here. If your graphics have minimal amounts of color and are simple in nature, silkscreen is your best bet.

Remember, each silkscreen color must be applied separately using a unique screen. So, the more colors you have in your graphics, the more screens that need to be created. This will increase your lead time and price. Therefore, if your graphics have several different colors (or colors beyond what our 16 stocked silkscreen colors), digital print will be your optimal choice.

Use Cases

Digital print is best used for graphics with high amounts of detail – such as a gradient finish, CGI effects or overlapping colors – or when multiple colors have to be used in a single graphic. If the graphics you want applied have gradient 3D effects or overlap in color, this is the way to go. Digital print offers a full spectrum of CMYK colors.

On the other hand, silkscreen makes sense for flat graphics with a limited number of colors. This is because each color needs to be silkscreened separately. When more colors are used, the longer it takes to silkscreen. Hence, it is better to choose digital print in such a situation.

Feel of Silkscreen and Digital Print

There is a noticeable difference in how silkscreen graphics feel compared to digital print.

Silkscreen ink is self-leveling. So, you can only feel a slight raised surface which produces a smooth finish that is virtually indistinguishable by touch. With digital print, meanwhile, you can feel the slightly raised texture of the graphics.

In the end, this comes down to your personal preference. Some engineers and designers prefer the feel of silkscreen, while others feel that digital print’s flexibility far outweighs its texture.

Digital Print Resolution Options

In 2022, we introduced two options for our digital print process – standard and premium resolution. Standard resolution, at 720 dots per inch (dpi), is a great choice for simple and small graphics, or applications where only text needs to be added. If you are looking at large color gradients or highly complex graphics, then premium resolution (1,440 dpi) is a better option.

Standard resolution is ideal for matte or low glass finishes, while premium is a better choice for high gloss, sandtex or bare metal finishes. You can find more information about digital print resolution options on our website and in our Proto Tech Tip video.

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