Photo Real Screen Printing in South Florida

How It Works

Photo Real printing (also known as simulated process) is an advanced screen printing technique that reproduces full-color, photorealistic images on garments using a limited number of spot-color ink screens. Unlike traditional CMYK process printing (limited to white/light garments), simulated process uses opaque plastisol spot colors layered with halftone dot patterns to blend and simulate a full spectrum of colors.

The Process

A white underbase is printed first on dark garments, followed by sequential color layers that build the image through overlapping halftone dots. The human eye blends these dots into continuous-tone, photorealistic imagery. Typically requires 6–11 screens depending on image complexity. The design must first be “separated." An art prep process that splits the image into individual color channels. This is a one-time fee that doesn’t apply to reorders.

Visual Effect

Photorealistic, full-color imagery with smooth gradients, fine detail, and vivid color reproduction on any garment color — including darks. The result rivals direct-to-garment quality with superior durability.

Technical Specs

• Ink Type: Opaque plastisol spot colors (PMS-matched); white underbase on darks
• Mesh Count: 155–305 (higher mesh for halftone detail)
• Cure Temp: ~320°F
• Best Fabrics: 100% cotton (ideal), cotton blends. Works on light and dark garments.

Pros

• Photorealistic results on any garment color including darks
• More stable and consistent in production than CMYK
• Uses standard plastisol inks — excellent durability
• Premium look that commands premium pricing
• One-time separation fee means reorders are faster and cheaper

Limitations

• Higher setup cost (color separations + 6–11 screens)
• Adds 3+ business days to turnaround
• Requires expert art preparation
• Some fine detail may be lost in separation
• Higher per-unit cost due to screen count