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I wanted to share some of my personal experiences with these systems, from the early days of ditching film to exploring high-end LTS setups. Whether you’re considering the switch to digital or just curious about the differences, here’s what it’s been like from my side of the press.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"id":"ceafbee5a4aa2db4de52a74e","type":"upload","value":{"id":437,"alt":"image 2 1 768x1024","prefix":"media","_objectKey":null,"updatedAt":"2026-09-18T18:38:37.568Z","createdAt":"2026-09-18T17:01:14.195Z","url":"https://files-cms.madelab.io/media/imgs__posts__4814__image-2-1-768x1024.jpeg","thumbnailURL":"https://files-cms.madelab.io/media/imgs__posts__4814__image-2-1-768x1024.jpeg","filename":"imgs__posts__4814__image-2-1-768x1024.jpeg","mimeType":"image/jpeg","filesize":106429,"width":768,"height":1024,"focalX":50,"focalY":50},"fields":{},"format":"","version":3,"relationTo":"media"},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Starting Out with Inkjet: The M&R i-Image S","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"At Shirt Kong, our first step into digital imaging was the M&R i-Image S inkjet unit. It was a massive improvement over printing film positives. Suddenly, we didn’t need to deal with films at all—no more storing them, no more lining them up on a vacuum table. Just load the art and print straight to the screen.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"That said, it wasn’t all smooth sailing.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"The ink had a tendency to spread or “gain”, especially when the humidity dropped or when a screen had been coated too long ago and dried out. I went so far as to mop the floor in the screen room daily just to keep the humidity in a usable range. Not ideal.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Maintaining the print head was also a bit of a nightmare. If you didn’t stay on top of cleaning—and I mean religiously—the print quality would tank. That meant lost screens and wasted time having to re-image them. Still, it was our first taste of going film-free, and that part was a game-changer.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Switching to Wax: The Douthitt Unit","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Eventually, we moved over to a Douthitt wax unit, and that changed everything for the better.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"First off, it didn’t care about humidity. Whether the air was dry or muggy, the wax system performed reliably. It also imaged screens faster than the inkjet and laid down a much more opaque image. That was a big deal. With the inkjet, I’d sometimes struggle to get a proper screen exposure. With the wax system, exposures were sharp, reliable, and detailed.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Maintenance was also almost a non-issue. No clogged heads, no constant cleaning schedules. Yes, the wax itself was more expensive as a consumable—but the peace of mind and consistency it gave me more than made up for that.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"If I had to pinpoint a moment where I felt like we hit our stride with digital imaging, it was after switching to wax.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"id":"bc2ded35102cd5eed34dca4f","type":"upload","value":{"id":441,"alt":"main image","prefix":"media","_objectKey":null,"updatedAt":"2026-09-18T18:38:37.568Z","createdAt":"2026-09-18T17:01:14.951Z","url":"https://files-cms.madelab.io/media/imgs__posts__4814__main-image.jpg","thumbnailURL":"https://files-cms.madelab.io/media/imgs__posts__4814__main-image.jpg","filename":"imgs__posts__4814__main-image.jpg","mimeType":"image/jpeg","filesize":218661,"width":1500,"height":2000,"focalX":50,"focalY":50},"fields":{},"format":"","version":3,"relationTo":"media"},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"The LTS Experience: Laser-to-Screen","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"I’ve had limited hands-on time with LTS (Laser-to-Screen) systems, but every time I’ve worked with one or seen it in action, I’ve been incredibly impressed.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"No ink. No wax. No consumables at all. The laser directly exposes the emulsion on the screen—no light table needed, no second step. The detail and sharpness of the stencils it produces is second to none.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Like any machine, it has its maintenance needs. You’ve got to clean the lenses and keep things tuned up, but that’s to be expected with any serious piece of equipment. What you get in return is unmatched precision and a simplified workflow.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"id":"a45a5e11a78624e3232fa2e4","type":"upload","value":{"id":438,"alt":"image 4 1024x683","prefix":"media","_objectKey":null,"updatedAt":"2026-09-18T18:38:37.568Z","createdAt":"2026-09-18T17:01:14.384Z","url":"https://files-cms.madelab.io/media/imgs__posts__4814__image-4-1024x683.jpeg","thumbnailURL":"https://files-cms.madelab.io/media/imgs__posts__4814__image-4-1024x683.jpeg","filename":"imgs__posts__4814__image-4-1024x683.jpeg","mimeType":"image/jpeg","filesize":118906,"width":1024,"height":683,"focalX":50,"focalY":50},"fields":{},"format":"","version":3,"relationTo":"media"},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"If I Had to Choose…","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"All three systems have their place. They’ve all helped push screen printing into a more digital, more efficient future.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"But if I had to choose? I’d go with either a wax system paired with a metal halide exposure table or a Laser-to-Screen system. They’ve both proven, in my experience, to offer higher consistency, better detail, and fewer headaches than inkjet.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"That said, inkjet is still a great entry point—especially for smaller shops looking to go digital without a huge upfront investment. The important thing is understanding what your shop needs now—and where you want it to go.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"id":"3dc5c086f6bdbe8b276fa357","type":"upload","value":{"id":439,"alt":"image 5 1024x682","prefix":"media","_objectKey":null,"updatedAt":"2026-09-18T18:38:37.568Z","createdAt":"2026-09-18T17:01:14.409Z","url":"https://files-cms.madelab.io/media/imgs__posts__4814__image-5-1024x682.jpg","thumbnailURL":"https://files-cms.madelab.io/media/imgs__posts__4814__image-5-1024x682.jpg","filename":"imgs__posts__4814__image-5-1024x682.jpg","mimeType":"image/jpeg","filesize":48351,"width":1024,"height":682,"focalX":50,"focalY":50},"fields":{},"format":"","version":3,"relationTo":"media"},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Final Thoughts","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Going digital changed the way we work. No more film storage, no more registration issues, no more wasted time lining things up by hand. 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","type":"text","style":"","detail":0,"format":0,"version":1},{"mode":"normal","text":"Education, Training & Support Manager","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":"—a role that perfectly blends his passion for screen printing with his knack for developing efficient, high-performing teams.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Kyle’s journey into screen printing started early—in high school shop class, pulling squeegees and printing shirts for local events and his punk rock bands. 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Training videos were hosted privately online, and the QR codes were printed and placed on each machine. This allowed team members to cross-train, troubleshoot, and fill in gaps—just by scanning and watching a short video.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"“We wanted to make it easy for anyone to step in and know exactly how to run a machine. 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HSA inks give beautiful results, but they demand precision, consistency, and a very different approach than what plastisol printers are used to.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"I recently ran an 8-color water-based job using Avient HSA inks, and while it turned out solid in the end, there were some very real challenges along the way. Here’s what I’d tell any plastisol-based shop owner or press op who’s looking to level up with water-based printing—what to expect, how to prepare, and how to avoid the typical pain points.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Also, if you’re serious about mastering WB, checkout to ","type":"text","style":"","detail":0,"format":0,"version":1},{"mode":"normal","text":"WB Camp","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":". It’s MADE Lab’s hands-on workshop in Orlando Florida. I wish I had made time for it back in 2022 when I worked at Shirt Kong but luckily, the next one is coming up—check it out here: ","type":"text","style":"","detail":0,"format":0,"version":1},{"id":"6aad760118068efb672230cc","type":"link","fields":{"url":"https://madelab.io/event/WBCamp2025?utm_source=chatgpt.com","newTab":false,"linkType":"custom"},"format":"","indent":0,"version":3,"children":[{"mode":"normal","text":"WB Camp 2025","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"type":"horizontalrule","version":1}],"direction":null,"textStyle":"","textFormat":0},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"1. Your Emulsion Needs to Match the Ink System","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"With water-based, and especially HSA inks, your screen emulsion choice is critical. If you’re using a general-purpose emulsion without a hardener, you’ll start seeing breakdown pretty early into a job—especially on multi-color runs.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Pro Tip:","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":" Use a water-resistant emulsion (or harden the one you’re already using), and ","type":"text","style":"","detail":0,"format":0,"version":1},{"mode":"normal","text":"always post-expose","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":". It’s a simple move that can make your screens last longer under harsh WB conditions.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":1},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"type":"horizontalrule","version":1}],"direction":null,"textStyle":"","textFormat":0},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"2. Watch Your Heat Management—It Will Bite You","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Multiple flashes, long dwell times, synthetic garments (like poly or Dri-Fit), and environmental heat can all compound into a major issue: ink drying in the screen. Water-based inks are heat-sensitive by nature, and HSA is even more unforgiving.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Pro Tip:","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":" Rotate hot platens, use cooling fans, lower flash temps if you can, and avoid overheating your pallets. Performance poly holds more heat than you think—it’ll sneak up on you.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":1},{"id":"338ae8613ba3f8530878efd1","type":"upload","value":{"id":336,"alt":"2 1024x682","prefix":"media","_objectKey":null,"updatedAt":"2026-09-18T18:38:37.568Z","createdAt":"2026-09-18T17:00:54.825Z","url":"https://files-cms.madelab.io/media/imgs__posts__4615__2-1024x682.jpg","thumbnailURL":"https://files-cms.madelab.io/media/imgs__posts__4615__2-1024x682.jpg","filename":"imgs__posts__4615__2-1024x682.jpg","mimeType":"image/jpeg","filesize":102891,"width":1024,"height":682,"focalX":50,"focalY":50},"fields":{},"format":"","version":3,"relationTo":"media"},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"type":"horizontalrule","version":1}],"direction":null,"textStyle":"","textFormat":0},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"3. Make Use of Your Auto Flood Settings","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"If your press has a “No Clean” or auto-flood feature, use it—especially during setup and test runs. One of the biggest drying risks comes from letting ink sit motionless in the screen while you’re dialing in registration or making micro tweaks.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Pro Tip:","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":" Flooding keeps the mesh covered, keeps ink moving, and buys you time. It’s a simple setting that can prevent major screen clogs.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":1},{"id":"b44823fef87debfceda6608f","type":"upload","value":{"id":456,"alt":"4 1024x548","prefix":"media","_objectKey":null,"updatedAt":"2026-09-18T18:38:37.568Z","createdAt":"2026-09-18T17:01:17.927Z","url":"https://files-cms.madelab.io/media/imgs__posts__4868__4-1024x548.jpeg","thumbnailURL":"https://files-cms.madelab.io/media/imgs__posts__4868__4-1024x548.jpeg","filename":"imgs__posts__4868__4-1024x548.jpeg","mimeType":"image/jpeg","filesize":60479,"width":1024,"height":548,"focalX":50,"focalY":50},"fields":{},"format":"","version":3,"relationTo":"media"},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"type":"horizontalrule","version":1}],"direction":null,"textStyle":"","textFormat":0},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"4. Don’t Sleep on Foggers or Humidity Control","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Slowing down during a job? Stepping away during setup? Those quiet moments are when water-based ink starts curing in your screen. A fogger or humidifier around the press can drastically help maintain open time.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Pro Tip:","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":" A cheap fogger can make all the difference on longer runs or setups, especially if you’re running multi-color on a slow-paced production schedule.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":1},{"id":"8c9f570e456560106371c1cc","type":"upload","value":{"id":457,"alt":"5 1024x768","prefix":"media","_objectKey":null,"updatedAt":"2026-09-18T18:38:37.568Z","createdAt":"2026-09-18T17:01:18.032Z","url":"https://files-cms.madelab.io/media/imgs__posts__4868__5-1024x768.jpg","thumbnailURL":"https://files-cms.madelab.io/media/imgs__posts__4868__5-1024x768.jpg","filename":"imgs__posts__4868__5-1024x768.jpg","mimeType":"image/jpeg","filesize":82437,"width":1024,"height":768,"focalX":50,"focalY":50},"fields":{},"format":"","version":3,"relationTo":"media"},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"type":"horizontalrule","version":1}],"direction":null,"textStyle":"","textFormat":0},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"5. Flood Bar Height & Ink Load Matter—A Lot","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"One of the biggest issues with water-based inks (especially HSA) is drying in the mesh. A big contributor? Not having enough ink in the screen and not keeping the image area properly flooded between strokes. If your flood bar is set too high or your ink deposit is too low, you’re basically inviting the ink to dry in place.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Pro Tip:","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":" Keep a healthy amount of ink in the screen, and make sure your flood bar is set low enough to fully cover and saturate the image area with each flood stroke. It’s not just about volume—it’s about coverage. A consistent, complete flood prevents dry spots, clogs, and downtime.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":1},{"id":"77bde3cc36e5b7c1b77dfccf","type":"upload","value":{"id":458,"alt":"6 1024x781","prefix":"media","_objectKey":null,"updatedAt":"2026-09-18T18:38:37.568Z","createdAt":"2026-09-18T17:01:18.055Z","url":"https://files-cms.madelab.io/media/imgs__posts__4868__6-1024x781.jpg","thumbnailURL":"https://files-cms.madelab.io/media/imgs__posts__4868__6-1024x781.jpg","filename":"imgs__posts__4868__6-1024x781.jpg","mimeType":"image/jpeg","filesize":131147,"width":1024,"height":781,"focalX":50,"focalY":50},"fields":{},"format":"","version":3,"relationTo":"media"},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"type":"horizontalrule","version":1}],"direction":null,"textStyle":"","textFormat":0},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"6. Use Retarders When You Need Them","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Retarder additives are your safety net. They slow the drying process and extend open time, which can be the difference between a smooth run and an hour of screen reclaim.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Pro Tip:","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":" If your press environment runs hot or you’re doing longer setups, mix in a little retarder. It won’t affect opacity or feel if dosed correctly, and it saves a ton of cleanup time.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":1},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"type":"horizontalrule","version":1}],"direction":null,"textStyle":"","textFormat":0},{"tag":"h2","type":"heading","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"7. Garment Selection Plays a Huge Role","type":"text","style":"","detail":0,"format":1,"version":1}],"direction":null},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Lightweight synthetics and moisture-wicking fabrics retain heat and don’t release it quickly. That added heat contributes to ink drying and ghosting problems—especially when running HSA.","type":"text","style":"","detail":0,"format":0,"version":1}],"direction":null,"textStyle":"","textFormat":0},{"type":"paragraph","format":"","indent":0,"version":1,"children":[{"mode":"normal","text":"Pro Tip:","type":"text","style":"","detail":0,"format":1,"version":1},{"mode":"normal","text":" If you’re new to water-based printing, start with cotton or blends before jumping straight into performance wear. 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