How Build Up Occurs

Multiple Ink Layers

Build up often results from printing multiple layers of ink, such as a white underbase followed by colour layers in screen printing.

High-Opacity or Specialty Inks

Certain inks, including blockout, puff, or metallic inks, naturally create more build up due to their formulation.

Repeated Print Passes

Running the squeegee over the same area multiple times increases ink deposit and overall print thickness.

When Build Up Is Beneficial

Improved Colour Coverage

Build up is sometimes necessary to achieve strong opacity on dark garments or heavily dyed fabrics.

Textured or Raised Effects

Specialty prints rely on controlled build up to create tactile finishes, such as puff prints or high-density logos.

Enhanced Durability

Adequate build up can improve ink adhesion, helping prints withstand frequent washing and wear.

When Build Up Becomes a Problem

Reduced Comfort

Excessive build up can make prints feel heavy, stiff, or less breathable on the garment.

Cracking and Peeling

Overly thick ink layers may crack or lift over time, especially on stretch fabrics.

Visual Issues

Too much build up can cause edges to appear rounded or distorted, reducing design sharpness.

Printing Methods and Build Up

Screen Printing

Screen printing is most prone to build up due to layered ink application. Proper mesh selection and squeegee technique help control thickness.

DTF Printing

DTF prints can develop noticeable build up if adhesive powder or ink layers are applied too heavily.

Embroidery and Transfers

While not ink-based, raised embroidery and layered transfers can also be described as having build up in terms of texture and thickness.

Practical Considerations for Managing Build Up

Ink Selection

Using the right ink formulation for the fabric and design helps achieve the desired coverage without excess thickness.

Mesh and Screen Setup

Higher mesh counts deposit less ink, reducing build up while maintaining detail.

Design Planning

Simpler designs often require less build up and result in cleaner, more comfortable prints.

Build Up vs Lightweight Printing

Lightweight prints prioritise softness and flexibility, while controlled build up focuses on opacity and impact. The best approach depends on the garment’s purpose and usage.

Why Managing Build Up Matters

Build up plays a significant role in both the look and feel of printed garments. For Australian custom apparel printers, controlling build up ensures prints are durable, comfortable, and visually appealing—meeting professional standards across workwear, promotional apparel, and fashion garments.