In the decorated apparel world, screen printing remains a top method for producing custom graphics. But when it comes to choosing the right ink, two major players dominate: Plastisol and water-based ink. So which one is best? The answer depends on your design, garment type, and goals.
Water-Based vs Plastisol: Which Ink Is Better?
The truth is, neither is universally better. Each ink type has its strengths and limitations depending on the job. Here’s how they compare across eight key factors:
1. Hand Feel: Water-Based Ink Wins
“Hand” refers to how a print feels on the garment. Water-based ink usually results in a softer, lighter feel, especially on lighter fabrics. It absorbs into the fibers, leaving virtually no texture in some cases.
Plastisol, on the other hand, sits on top of the fabric, resulting in a thicker print with a heavier feel.
Bonus: Discharge Ink
Used with water-based inks, discharge ink chemically removes dye from garments, creating a softer base on dark fabrics—but only works well on 100% cotton.
Bottom line: Water-based inks create a softer, lighter print.
2. Color Vibrancy: Plastisol Takes the Lead
Plastisol produces brighter, more vibrant colors—especially on dark garments—because it creates a solid, opaque ink layer. It’s ideal when you need your design to pop.
Water-based inks are more transparent and perform best on light fabrics. Vibrancy suffers on dark shirts unless discharge is used.
Bottom line: For vivid, eye-catching colors, choose Plastisol.
3. Color Accuracy: Plastisol Again
If your design demands Pantone-level precision or consistent brand colors, Plastisol offers unmatched color accuracy.
Water-based inks, while improving, can suffer from shifts in shade and reduced saturation, particularly on darker garments.
Bottom line: Plastisol excels in color matching.
4. Durability: It’s a Tie
Both inks can produce prints that last the life of the garment if cured properly.
Plastisol forms a solid bond on top of the fabric, while water-based inks penetrate the fibers.
Bottom line: Properly applied, both inks offer excellent durability.
5. Breathability: Water-Based Ink Wins
Water-based inks allow moisture and air to pass through the fabric more easily, offering better breathability.
Plastisol’s thick, plastic-like surface can trap heat and moisture, creating what some call a “sweat patch.”
Bottom line: For breathable prints, go with water-based.
6. Versatility: Plastisol Is More Flexible
Plastisol can be printed on a wide range of fabrics including polyester, blends, and synthetics.
Water-based inks are best suited for 100% cotton. On blends or synthetics, they may underperform or require special additives.
Bottom line: Plastisol wins on garment versatility.
7. Eco-Friendliness: Slight Edge to Water-Based
Water-based inks are often marketed as more eco-friendly because they’re PVC-free and contain fewer harmful chemicals.
However, they still require co-solvents like formaldehyde and alcohol, and curing them uses more energy.
Plastisol contains PVC but produces less waste due to higher yield and ease of disposal (once cured).
Bottom line: Sustainability depends more on printer practices than ink type alone.
8. Cost and Ease of Use: Plastisol Is More Practical
Plastisol ink is generally cheaper and easier to work with, making it the go-to for many print shops.
Water-based inks require more care, precise conditions, and tend to be priced as a premium option.
Pro Tip for Printers: Plastisol is stable, versatile, and easy to use. Water-based requires additives, careful setup, and experience.
Bottom line: Plastisol is more cost-effective and user-friendly.
Final Verdict: RushOrderTees Recommends Plastisol
Plastisol delivers top-tier vibrancy, accuracy, durability, and flexibility—all at a lower cost. While water-based inks shine for their soft feel and breathability, they come with limitations in vibrancy, versatility, and cost.
Summary:
- Want a soft, vintage print on cotton? Choose water-based.
- Need bold colors and versatility across garments? Choose Plastisol.