Specialty Screen Printing Inks: Puff, Metallic & More

TL;DR - Beyond Standard Ink

Standard plastisol and water-based inks handle 90% of jobs. The other 10% is where specialty inks create prints that stop people in their tracks. Puff raises the print into a 3D texture. Metallic/chrome creates a molten-metal shine. Glow-in-the-dark charges in light and glows for hours in the dark. Reflective lights up when hit by headlights or flashlights. High-density builds thick, raised designs with sharp edges. Battle Born runs specialty inks from AllureGlow USA (reflective and glow-in-the-dark) and Total Ink Solutions (metallic gold, chrome, puff) on our M&R GT-8. These inks cost more than standard plastisol, but the visual impact is worth it for the right project.

Puff ink is not a standalone ink - it is an additive mixed into standard plastisol. The additive contains a chemical foaming agent that activates when heated. During curing, the ink literally puffs up, creating a raised 3D texture you can feel with your fingers. The effect is dramatic on bold lettering and simple graphic shapes. We mix at 15-30% depending on how much rise the customer wants. Lower percentage = subtle texture. Higher percentage = pronounced dome.

Limitations: Puff distorts fine detail because the expansion is not perfectly uniform. Small text, thin lines, and halftone dots should not be printed with puff. It also adds significant hand feel and weight to the print. Keep designs bold and simple for the best result. Flash carefully between colors - you do not want the puff to activate before the top colors are printed.

Metallic inks contain reflective metallic flakes suspended in plastisol. When printed and cured, the flakes lay flat and catch light, creating a genuine metallic shimmer. The effect ranges from subtle shimmer (smaller flakes) to aggressive chrome mirror finish (larger, denser flakes). We run Total Ink Solutions metallic series for gold, chrome, rose gold, gun metal, and silver. Their Low Cure Metallic Stretch formulation is phthalate-free and does not require an underbase - print two hits directly onto the garment.

Pro tip: Metallic finishes reflect heat in the dryer, which can make curing tricky. The surface temp reads hot on an IR gun but the ink core may not have reached fusion. Always verify cure with a wash test or donut probe. Flash between colors at 220F for 3-5 seconds. The reflective attribute can extend flash time compared to standard plastisol.

Glow-in-the-dark (photoluminescent) ink contains phosphorescent pigments - typically strontium aluminate - that absorb light energy and slowly release it as visible glow. Under normal lighting, the print looks like a standard color. After charging in sunlight (10 min) or artificial light (30 min), the pigments emit a bright glow that lasts hours in darkness.

We run AllureGlow USA plastisol glow inks - phthalate-free, soft hand, available in multiple daytime/glow color combinations. These are premium inks (priced well above standard plastisol), but the effect is unlike anything else in screen printing. Use a white underbase on dark garments for maximum glow intensity - the white reflects more light energy into the phosphorescent pigment layer.

Can you halftone glow-in-the-dark ink? Yes - and the results are incredible. Halftoning glow ink creates a gradient glow effect where darker areas glow brighter and lighter areas fade off, adding depth and dimension that solid glow prints cannot match. The artwork below by Firman demonstrates this technique:

Reflective ink is fundamentally different from glow-in-the-dark. Glow ink charges and emits its own light. Reflective ink contains retroreflective glass beads that bounce incoming light back toward its source. In normal lighting, the print looks like a standard color. When hit by a direct light source - car headlights, flashlights, camera flash - the print explodes with brilliant reflectivity.

We use AllureGlow USA PS Series reflective plastisol inks. Phthalate-free, soft hand, designed for cotton and 50/50 blends. Available in multiple daytime colors that all reflect white/silver when hit with light. These are pricey inks, but the results speak for themselves - especially for mining and construction crews who need hi-vis apparel, night run events, and safety-conscious organizations.

Key note for Nevada customers: This ties directly into our mining and construction workwear service. Reflective ink on hi-vis garments adds a custom branding layer on top of standard safety compliance.

High-density (HD) ink is a thick-bodied plastisol designed to build up in layers for a pronounced raised effect with sharp, defined edges. Unlike puff (which expands chemically), high-density achieves its height through pure ink thickness - multiple print-flash-print passes stacking ink on ink. The result is a smooth, sculpted raised print that holds crisp edges and fine detail much better than puff.

HD vs Puff: Puff is cheaper and faster (one pass + heat activation) but distorts fine detail. HD is more labor-intensive (multiple passes with flashing between) but produces a cleaner, more controlled raised effect. HD is the premium choice for brand logos and text where edge quality matters.

Suede ink creates a soft, matte, velvety texture that looks and feels like actual suede fabric. It is a plastisol additive (similar to puff) that changes the surface texture rather than adding height. The result is a luxurious tactile finish that stands out on premium brand prints, upscale event merch, and fashion-forward designs. Print through 86-156 mesh and cure at standard plastisol temps. The suede effect activates during curing.

"While special effects printing may not always be the most profitable service, it is a great way to gain attention. Discharge printing isn't just another technique - it's a way to create high-quality, fashion-forward prints that set your shop apart."

- John from Avient, via ScreenPrinting.com / Impressions Expo 2025

Want a Print That Stops People in Their Tracks?

Battle Born stocks specialty inks from AllureGlow USA and Total Ink Solutions. Glow-in-the-dark, reflective, metallic gold, chrome, puff, high-density, suede - we run them all on our M&R GT-8. Tell us what effect you are after and we will recommend the right ink and produce a sample before your full run.