The Process of Custom Puff Printing on Shirts

Custom puff printing, also known as 3D or foam printing, is a popular technique that adds a unique, raised texture to printed designs on shirts. This method creates a visually striking and tactile effect, making it a favorite for logos, typography, and other graphic elements. In this comprehensive guide, we will walk you through the process of custom puff printing on shirts, from the materials and tools needed to the step-by-step procedure and best practices for achieving high-quality results.

Materials and Tools Needed

To get started with puff printing, you’ll need the following materials and tools:

  • Puff Additive or Puff Ink: A special additive that is mixed with plastisol ink to create the raised effect.
  • Plastisol Ink: The base ink used in screen printing, known for its durability and vibrant colors.
  • Screen Printing Frame and Mesh: A frame with a fine mesh screen that holds the stencil for your design.
  • Emulsion and Emulsion Coater: A light-sensitive coating used to create the stencil on the screen.
  • Exposure Unit: A device that uses light to transfer your design onto the emulsion-coated screen.
  • Squeegee: A tool used to spread ink across the screen and push it through the stencil onto the fabric.
  • Heat Press or Conveyor Dryer: Equipment used to cure the ink and activate the puff effect.
  • T-shirts: High-quality shirts suitable for screen printing.
  • Degreaser and Screen Cleaner: Products used to clean the screen before and after printing.

Step-by-Step Puff Printing Process

1. Design Creation

  • Conceptualize Your Design: Create a design that benefits from the raised effect of puff printing. Bold, simple graphics and text work best for this technique.
  • Digitize the Design: Use graphic design software to create a high-resolution digital file of your design. Ensure it is suitable for screen printing.

2. Preparing the Screen

  • Coat the Screen with Emulsion: Apply a thin, even layer of emulsion to both sides of the screen using an emulsion coater. Allow the emulsion to dry in a dark, dust-free environment.
  • Expose the Screen: Place your design printed on a transparent film onto the emulsion-coated screen and expose it to light using an exposure unit. The light hardens the emulsion, except where the design blocks it.
  • Develop the Screen: Rinse the screen with water to wash away the unhardened emulsion, leaving a stencil of your design.

3. Mixing Puff Ink

  • Prepare the Ink: Mix the puff additive with plastisol ink according to the manufacturer’s instructions. The ratio typically varies, but a common mix is one part puff additive to four parts plastisol ink.
  • Stir Thoroughly: Ensure the puff additive is evenly distributed throughout the ink to achieve a consistent puff effect.

4. Setting Up for Printing

  • Position the Shirt: Place the shirt on the printing surface, ensuring it is smooth and properly aligned.
  • Align the Screen: Position the screen over the shirt, making sure the stencil aligns correctly with the desired print area.

5. Printing the Design

  • Apply the Ink: Pour a small amount of the mixed puff ink at the top of the screen.
  • Spread the Ink: Use the squeegee to pull the ink across the screen, pressing it through the stencil onto the shirt. Apply consistent pressure to ensure an even layer of ink.
  • Check the Print: Lift the screen and inspect the print. Make sure the ink coverage is even and there are no gaps or smudges.

6. Curing the Ink

  • Heat Cure the Print: Use a heat press or conveyor dryer to cure the ink. The temperature and time will depend on the specific puff additive and plastisol ink used, but a common setting is 320°F (160°C) for 2-3 minutes.
  • Activate the Puff Effect: The heat causes the puff additive to expand, creating the raised, textured effect. Ensure the entire design is exposed to heat evenly to achieve a uniform puff.

7. Final Touches

  • Inspect the Finished Shirt: Check the shirt for any imperfections or areas that did not puff up correctly. If necessary, you can touch up the print with additional ink and heat.
  • Clean the Screen: After printing, clean the screen thoroughly with a screen cleaner to remove any residual ink and emulsion.

Tips for Successful Puff Printing

1. Choose the Right Design

Bold, simple designs with thick lines and large areas of color work best for puff printing. Fine details may not puff evenly and can be lost in the process.

2. Proper Mixing

Ensure the puff additive is mixed thoroughly with the plastisol ink. Inconsistent mixing can lead to uneven puffing and an unsatisfactory final product.

3. Consistent Pressure

Apply consistent pressure when spreading the ink with the squeegee. Uneven pressure can result in varying ink thicknesses, affecting the puff effect.

4. Accurate Curing

Proper curing is crucial for activating the puff effect. Follow the manufacturer’s guidelines for temperature and time to ensure the ink puffs correctly and adheres well to the fabric.

5. Test Prints

Perform test prints on scrap fabric to fine-tune your process. This allows you to adjust the ink mix, screen alignment, and curing settings before committing to the final print.

6. Quality Materials

Use high-quality shirts, inks, and additives. Investing in good materials results in a better print and a more durable, professional-looking product.

Creative Applications of Puff Printing

1. Branding and Logos

Puff printing is ideal for creating standout logos on t-shirts, hoodies, and other apparel. The raised effect adds a tactile dimension to your brand identity.

2. Custom Merchandise

Create unique merchandise for bands, sports teams, or events. Puff printing can make your designs more attractive and memorable.

3. Fashion Statements

Design bold fashion pieces with puff printing. The technique adds texture and interest to otherwise plain garments.

4. Special Occasions

Puff printing can be used to create custom shirts for special occasions like weddings, birthdays, or reunions. Personalized designs with a 3D effect make great keepsakes.

5. Art and Graphics

Experiment with artistic designs and graphics. The raised effect of puff printing adds depth and dimension, enhancing the visual appeal of your artwork.


Puff printing is a versatile and eye-catching method for creating custom shirts. By following the steps outlined in this guide, you can achieve professional-quality results that stand out from traditional flat prints. Whether you’re making shirts for personal use, gifts, or to sell, puff printing offers a unique way to add texture and interest to your designs. With the right materials, tools, and techniques, you’ll be able to create stunning, raised prints that make a lasting impression.