“You can’t screen print more than 4 colors.”

This is a common misconception in the apparel industry. Although it’s true that traditional screen printing can’t efficiently produce a large number of colors, there are ways around this limitation!

If your brand strives to achieve vibrant, photorealistic designs on custom apparel, simulated process screen printing offers a top-tier solution. 

This advanced technique delivers unmatched print quality, capturing the kind of intricate detail that standard screen printing methods can’t replicate. 

For brands focused on creating premium, eye-catching designs that are screen printed on a cotton-based fabric, simulated process printing is the answer.

With simulated process screen printing, you can achieve up to 16-color designs, handle large-scale prints, and ensure outstanding durability even after multiple washes. 

Ready to learn more? Let’s break down how this method supports the needs of streetwear brands and many kinds of custom apparel projects.

Learn More About Scrappy’s Simulated Process Printing Services

What is Simulated Process Screen Printing?

Simulated process screen printing is a sophisticated method that brings complex designs to life with precise, high-color details. Using a combination of halftone dots and spot colors, it creates the illusion of a wide color spectrum with only 8-12 colors. You’ll end up with high-definition prints that stand out on any garment!

How Simulated Process Differs from Standard Screen Printing

One drawback of traditional screen printing is its color limitations. Because it requires a separate screen for each color, regular screen printing can get expensive—fast.

However, simulated process printing offers a solution—it layers colors strategically to produce a vast range of hues. 

Specialized software handles color separations while considering the garment’s base color, allowing for smooth gradients and intricate detail. 

This technique’s advantages include:

• Exceptional Detail Capture: Perfect for intricate artwork and detailed designs.
• Versatile Printing on Any Garment Color: The method adapts seamlessly to various base colors.
• Efficient Production: Faster print times with possible flashing for added durability.
• Ink Compatibility: Works well with water-based and PVC-free inks.

Ideal for High-Color, Photorealistic Prints

For designs that rely on realistic imagery and fine details, simulated process printing is unparalleled. 

This method excels in handling:

• Smooth Color Transitions
• Complex Shadows and Gradients
• Detailed Artwork
• Natural and Photorealistic Images

A white underbase on darker fabrics enhances color vibrancy, ensuring the design stays true to its original look.

Bring Your Designs to Life with Laser Precision

Simulated process printing is perfect for creating complex, photorealistic designs with vivid color gradients and fine detail. It reproduces visuals with remarkable accuracy, making it versatile and ideal for streetwear. 

With the ability to combine simulated process printing with techniques like embroidery, your brand can achieve truly unique and eye-catching results.

Garments That Work Well with Simulated Process

Like every printing process, there are fabrics that work well and ones that don’t.

Polyester is a no-go for screen printing. If you want to print on polyester, sublimation is a far better printing process.

Cotton-based fabrics work the best—but again, not all are created equal. Lightweight cotton, while breathable and comfortable, often lacks the structure needed to capture the high detail and vibrancy that this printing technique offers. It’s better suited for other use cases.

We recommend using premium heavyweight cotton for streetwear-inspired prints. This fabric provides the stable, dense surface needed to ensure that intricate designs stay crisp and colors stay true. Heavyweight cotton is also incredibly durable, allowing your prints to look bold and vibrant, even after repeated washes. 

Leading brands like Shaka Wear highlight the premium quality achievable with high-grade blanks for simulated process screen printing. Their heavyweight 6.5oz tees are expertly designed with streetwear aesthetics in mind. This quality fabric provides an ideal surface for simulated process printing, which thrives on materials that can capture intricate details and vibrant colors.

Another great example is the Lane Seven Unisex Urban Heavyweight T-Shirt (Style LS16005). This garment is made from 100% combed ringspun cotton, providing a durable surface ideal for detailed printing techniques. Its pure cotton composition offers superior breathability and comfort, while still maintaining the premium feel and printability that Lane Seven is known for.

Scrappy Apparel’s Advanced Screen Printing Services Ensure Quality, Vibrancy, and Durability

At Scrappy Apparel, our screen printing solutions bring your designs to life with unmatched color depth, precision, and durability. Our extensive capabilities and refined processes allow you to create apparel that truly makes a statement with its visual impact and lasting quality.

Why Choose Scrappy Apparel?

Partnering with Scrappy means working with a team that’s committed to precision, consistency, and the highest quality standards:

• 16-Color Printing for Maximum Vibrancy: Our high-tech 16-color printing system captures stunning gradients, photorealistic details, and precise color matching. This technology allows for true-to-life prints that maintain brand consistency and bring intricate designs to life.
• Monster Prints for Bold, Large-Scale Designs: Our monster screen print technology ensures large-scale designs retain sharpness and vibrant colors across extensive print areas, making it ideal for bold, statement pieces. This capability allows your brand to stand out with designs that demand attention and make a lasting impression. You can print up to 17” x 22” with us, which most local print shops can’t compete with!
• Fast, Reliable Production for High-Demand Orders: With our agile manufacturing processes, we deliver quick turnarounds without compromising quality. Whether you’re launching a new collection or restocking popular items, our streamlined production keeps your schedule on track, ensuring you can meet market demand effectively.
• High-Detail Printing Expertise: Our team offers 18+ years of experience in handling intricate designs.
• Dedicated Quality Control: From pre-press artwork checks to post-production inspections, we maintain rigorous quality control throughout, guaranteeing consistent and reliable results.
• Full-Service Manufacturing and Fulfillment: Our fulfillment solutions ensure fast, efficient delivery to each final destination, keeping your brand’s reputation intact.

Ready to Become Our Next Scrappy Success Story?