Why Dot Gain Occurs

Dot gain occurs due to a combination of physical and visual factors.

Ink Absorption

Fabrics, especially cotton and blended materials, absorb ink differently than paper. As ink penetrates the fibres, it naturally spreads beyond the original dot size.

Printing Pressure and Heat

In processes like screen printing and heat curing, pressure and temperature can cause ink to expand slightly on the garment surface.

Fabric Texture

Textured or loosely woven fabrics create uneven surfaces, allowing ink to spread more than it would on smooth materials.

Types of Dot Gain

Dot gain generally falls into two categories:

Mechanical Dot Gain

This occurs when ink physically spreads on the garment due to pressure, ink viscosity, or fabric absorption. It is most noticeable on soft, absorbent fabrics.

Optical Dot Gain

This is a visual effect caused by light scattering within the fabric fibres, making printed dots appear larger or darker to the eye even if they have not physically spread.

Both types can affect print clarity and colour accuracy if not properly managed.

How Dot Gain Affects Garment Printing

Dot gain can influence several aspects of a finished garment:

• Darker colour appearance, especially in mid-tones
• Loss of fine detail, particularly in small text or intricate designs
• Reduced sharpness in photographic or gradient artwork
• Colour inconsistency across different fabric types

For Australian businesses ordering branded apparel, unmanaged dot gain can result in prints that differ from approved artwork or brand guidelines.

Managing Dot Gain in Professional Printing

Experienced garment printers use several techniques to control dot gain:

Artwork Preparation

Design files are adjusted during pre-press to compensate for expected dot gain, particularly for screen printing.

Ink Selection

Using the correct ink type and viscosity helps minimise unwanted spreading.

Fabric Selection

Tighter-weave fabrics typically produce sharper results with less dot gain.

Testing and Proofing

Test prints and design proofs help identify dot gain issues before full production.

Dot Gain and Different Printing Methods

Dot gain varies depending on the printing technique:

• Screen printing may experience higher mechanical dot gain due to ink thickness and pressure.
• DTG printing can show dot gain on highly absorbent cotton fabrics.
• Dye sublimation typically has minimal dot gain, as the dye bonds within polyester fibres rather than spreading on the surface.

Understanding these differences helps select the most suitable printing method for each project.

Why Dot Gain Matters

Dot gain is a technical but essential concept in professional garment printing. By anticipating and managing dot gain, printers can deliver accurate colours, clean detail, and consistent quality. For Australian businesses relying on custom apparel to represent their brand, proper control of dot gain ensures the final product meets expectations and professional standards.