How to Use Champion Inks Stretch Polyester Plastisol Ink

Champion Inks Stretch Polyester Plastisol Ink is engineered for high-movement garments like sports jerseys, leggings, compression wear, and performance polyester. This ink is designed to flex without cracking, block dye bleed on polyester, and deliver long-lasting, professional print quality wash after wash.

Why This Ink

This is not hobby ink. This is production-grade ink for real print shops. You get high opacity on dark polyester, smooth printability, soft hand feel, and a flexible cured ink film that moves with the fabric instead of breaking. It is built for 100% polyester, poly blends, athleisure, team uniforms, gym apparel, and stretch fabric where normal plastisol would crack or peel.

Recommended Use Cases

• Sports jerseys and athletic uniforms
• Polyester hoodies and lightweight performance hoodies
• Leggings, compression tops, activewear, gym merch
• Moisture-wicking shirts and sublimated polyester garments

If you are printing on polyester, poly/spandex, or any fabric that stretches and rebounds, this is the ink system you should be using.

Step-by-Step Printing Instructions

1. Screen and Mesh Selection

For strong coverage and maximum flexibility, start with a lower mesh count (around 110). A slightly heavier ink deposit helps block bleed and improves stretch life. For lighter garments or fine detail, you can go a bit higher mesh, but do not choke the ink. You want enough ink on the shirt to stretch without cracking.

2. Print Technique

Set a proper off-contact gap so the screen snaps clean and does not smear. Use a medium blade and controlled pressure instead of smashing the screen into the fabric. Smooth, even passes will give you a consistent film that lays flat and cures correctly.

For high-opacity white or bright colors on dark polyester, many shops run print / flash / print. This builds a strong base layer and improves both coverage and bleed resistance.

3. Flashing Between Layers

Flash only to gel the surface, not to fully cure. The ink should be just dry to the touch before the next layer. Do not overheat the polyester on-press. Too much heat during flashing can trigger dye bleed on performance fabrics.

4. Cure and Final Fusion

Plastisol must be fully cured through the entire ink layer, not just on the surface. Stretch Polyester Plastisol Ink is formulated for lower cure temperatures than standard plastisol. That protects heat-sensitive polyester and helps reduce dye migration.

Run a slower belt with controlled heat so the full ink film reaches the correct cure temperature. Use a laser temp gun or probe directly on the print, not just in the dryer air. After cure, stretch the print in both directions. A properly cured print should flex and recover without cracking, lifting, or splitting.

Always wash test one sample shirt before full production. This protects you from costly reprints.

Controlling Dye Bleed on Polyester

Polyester fabrics (especially reds, neons, and fully sublimated jerseys) can release dye under heat. That dye can creep into the ink and discolor the print. Our Stretch Polyester Plastisol Ink is built to help control this by allowing lower cure temperatures and by supporting heavier, more controlled ink deposits.

For extremely aggressive fabrics, you can lay down a bleed-blocking underbase first, flash lightly, then print your stretch color on top. This creates a barrier layer so your final color stays clean and bright.

Extreme Stretch Applications

For high-flex zones like leggings, waistbands, elbows, shoulders, and compression panels, you need an ink film that can move repeatedly without breaking. Our Stretch Polyester Plastisol Ink is formulated for flexibility and recovery after stretch when correctly cured.

If you are pushing the fabric beyond normal stretch (heavy compression wear, gym tights, certain dancewear), you can build up a protective base layer and then print your color on top for even more durability. This helps the print survive repeated bending, pulling, and high-tension movement.

Quality Checklist for Your Shop

• Test the exact garment you are printing, not just a random sample shirt.
• Document mesh count, squeegee pressure, flash temp, belt speed, and cure temp for repeat jobs.
• Stretch test after cure. If it cracks, it is not fully fused.
• Wash test before delivering to the customer.

Why Print Shops Choose Champion Inks

Champion Inks is focused on real shop results: coverage, stretch, cure confidence, and wash durability. We build inks for production printers who need output they can hand to paying customers without worry. Our Stretch Polyester Plastisol Ink is designed to solve the two biggest problems with polyester printing: cracking and dye bleed. The goal is simple — clean color, flexible print, no returns.

Need Help With Settings?

If you’re running into cracking, undercure, dye migration, or you are moving from cotton to polyester for the first time, contact us. Tell us the garment style, fabric type, mesh count you’re using, and your dryer settings. We can help you dial in faster and avoid wasted stock.

SEO Summary

Champion Inks Stretch Polyester Plastisol Ink is a professional low-cure, high-stretch screen printing ink for polyester, athletic wear, compression fabric, and performance blends. Built for opacity, flexibility, and long-term wash durability. Ideal for sports jerseys, leggings, and high-movement apparel. Trusted by production shops.