Ink is the part of a screen print you actually touch. It decides how the print feels, how it looks on dark fabric, and how it holds up in the wash. This guide compares plastisol vs water based ink, plus discharge, in plain terms.
We pulled the details from ink makers and printing education pages, and we list every source at the end. If you are planning a custom run, it helps to know these words before you talk to any printer.
The short version
- Plastisol sits on top of the fabric. It is bright, opaque and forgiving to print, with a thicker feel.
- Water-based ink soaks into the fibres. It feels softer and breathes, but it depends more on the fabric and the shirt colour.
- Discharge ink removes the garment's dye and replaces it with colour. It feels very soft, but it only works well on cotton.
None of them is best for every job. The right pick depends on the garment, the design and how you want the print to feel.
How plastisol ink works
Plastisol is a PVC-based ink. Permaset describes it as pigment and resin particles, usually PVC, suspended in a plasticiser. ScreenPrinting.com calls it a "100% solid ink system," which means there is nothing in it to evaporate.
That has a practical upside. Plastisol does not dry out in the screen, so a printer can leave ink on a screen overnight and keep printing the next morning. ScreenPrinting.com also notes it is more forgiving if a screen's exposure is not perfect.
Plastisol only cures with heat. Most textile plastisol cures somewhere between 300°F and 330°F, according to ScreenPrinting.com. Low-cure versions exist too. Wilflex, a brand from Avient, lists some of its Epic ink lines at a low cure of 270°F (132°C).
How water-based ink works
Water-based ink uses water as the main carrier. Permaset describes it as pigment in a water-based medium, usually with acrylic polymers as the resin. Instead of sitting on top, it soaks into the fibres.
Curing takes two steps. First the water has to evaporate, then the ink has to reach cure temperature and hold there. ScreenPrinting.com's help centre says to hold at temperature for at least 20 seconds once the water is gone. For Green Galaxy inks it suggests three minutes at 300°F to 320°F, or at least 90 seconds at 360°F.
The catch is drying in the screen. ScreenPrinting.com warns that water-based ink left in open mesh "for even a short period of time" can clog the mesh and ruin the screen. Printers wipe screens before breaks. Screens also need a water-resistant emulsion.
How discharge ink works
Discharge works differently from the other two. It does not just add colour. It removes the dye already in the garment, bringing the fabric back toward its natural fibre colour, then adds pigment in its place.
To do this, the ink needs an activator mixed in. ScreenPrinting.com says the common one is zinc formaldehyde sulfoxylate (ZFS), with thiourea dioxide as a less common option. The activator starts working around 230°F, and dye removal is mostly done by 260°F. The ink still has to be fully cured like any water-based ink.
Discharge can print every colour, or it can act as a soft base under plastisol colours on top. Once mixed with activator, it has a limited pot life, so printers mix only what they need.
Feel and look: the hand of each ink
Printers call the feel of a print its "hand." This is where the three inks differ most.
| Ink | Feel | Look |
|---|---|---|
| Plastisol | Thicker, more rigid layer on top of the fabric | Bright, opaque, semi-gloss |
| Water-based | Thin, soft, flexible, breathable | Matte; brightness depends on the shirt |
| Discharge | Very soft; the ink becomes part of the fabric | Vintage feel; results vary by garment |
Real Thread says plastisol always prints bright because it sits on top. Water-based prints look bright on 100% cotton but "more toned down" on blends. Permaset adds that plastisol has almost no breathability, while water-based feels better against the skin.
Durability in the wash
All three can last when they are cured properly. An undercured print is the real enemy. ScreenPrinting.com notes that proper curing is what stops water-based prints from washing off.
Still, they age differently. Real Thread says plastisol "can crack, peel, or flake off with long wear," while water-based prints can last as long as the garment. Permaset notes plastisol can crack as its plasticiser breaks down over time. Plastisol also cannot be ironed directly, because the heat will smear it.
For care tips that help any print last, see our guide on how to wash screen printed t-shirts.
Which fabrics each ink suits
Plastisol
Plastisol works on a wide range of finished garments, including tees, sweatshirts and jackets. Real Thread notes its opacity makes it reliable on dark garments, whatever the blend.
Polyester needs extra care. Dyes in polyester can move into the ink, which printers call bleed or dye migration. Wilflex makes low-bleed whites and a dye migration blocker for this problem.
Water-based
Water-based ink shines on cotton and soft, breathable fabrics. Permaset says opaque water-based formulas can handle dark fabrics. Green Galaxy's Comet White is marketed for polyester and dye-migrating fabrics when used with its low-cure catalyst.
Discharge
Discharge needs 100% cotton or high-cotton blends, ideally with reactive dyes. ScreenPrinting.com says polyester, rayon and synthetic blends "will not discharge evenly, if at all." Heathered and tri-blend fabrics may give a textured, uneven effect. Over-dyed garments often resist discharge too.
Because results depend on how each garment was dyed, discharge is usually test-printed first. If you are still choosing blanks, our post on the best blank t-shirts for screen printing covers the options.
Eco and safety considerations
No ink is impact-free, so it helps to look at the details.
- Plastisol contains PVC. Permaset says it involves hazardous chemicals through manufacturing, use and disposal. Cleanup needs oil-based cleaners. On the other hand, ScreenPrinting.com notes cured plastisol is not considered hazardous waste in most municipalities.
- Water-based ink cleans up with water and few chemicals, according to ScreenPrinting.com. Green Galaxy describes its Comet White as phthalate and PVC free. But wastewater still needs solids capture, and catalyzed ink needs hazardous waste disposal unless fully dried.
- Discharge ink uses a formaldehyde-based activator in most systems. ScreenPrinting.com says never to cure it in an unvented dryer and not to fold and pack garments right after printing. It also advises against discharge for kids' apparel that is not CPSIA-certified.
Real Thread also notes water-based ink tends to cost more than plastisol. That can affect your quote, so ask about it early.
How to choose for your project
- Want bold, bright colour on dark shirts or mixed fabrics? Plastisol is the dependable choice.
- Want a soft, breathable print on light cotton? Water-based is a strong fit.
- Want a soft, vintage look on dark 100% cotton? Ask about discharge, and plan for a test print.
- Printing on polyester or performance wear? Ask about low-bleed options.
When you order screen printing from us, tell us how you want the print to feel and what garment you are using. We include design help and give you a full quote before anything is printed. You can also contact us with questions first.
Questions people ask
Is water-based ink better than plastisol?
Not in every case. Water-based feels softer and breathes more. Plastisol is brighter, more opaque and easier to print on dark or blended fabrics.
Can discharge ink be used on polyester?
Not reliably. ScreenPrinting.com says polyester, rayon and synthetic blends will not discharge evenly, if at all. It works best on 100% cotton or high-cotton blends.
Why does a print feel thick or rubbery?
That usually means a heavy plastisol layer sitting on top of the fabric, often with a white underbase. Water-based and discharge inks soak in, so they feel thinner.
Does plastisol crack?
It can over time. Real Thread and Permaset both note plastisol may crack with long wear as the ink ages.
Sources
- ScreenPrinting.com (Ryonet): Plastisol Ink vs Water Based Ink
- ScreenPrinting.com: Printing with Plastisol vs. Water Based Ink
- ScreenPrinting.com Help: How do you cure water-based ink?
- ScreenPrinting.com: Discharge Ink and Discharge Screen Printing, How It Works
- ScreenPrinting.com: When To Use Discharge Ink (And When Not To)
- Permaset: Water-based ink vs plastisol ink
- Real Thread: Water-Based Ink vs. Plastisol
- Avient: Wilflex Epic Low Cure Plastisol Inks
- Green Galaxy: Comet White HSA Water Based Ink
Written by XUSI, an Indigenous-owned clothing and screen printing brand from Saskatoon on Treaty 6 territory. Our story · What the words mean