Note: This project needs quite a bit of materials, these include:
 

- Three colors of ink: white, red, and orange. (Speedball brand recommended)

- An xTools screen printer.

- 3coated screens.

- A drying tool: either a hairdryer, heat press, or heat gun.

- A dark-colored shirt.

To begin this project, follow these steps in xTools Creative Space:

1. Change "Process on Flat Surface" to "Screen Preparation."

2. Calibrate the Origin by moving the laser head to the corner of the screen and displaying the engravable surface on the workspace.

3. Adjust the Easy Set settings to 100% power and 135 speed. These are not the default recommendations but have been found to be more effective.

4. If you have an Air Assist, ensure it is turned off. Using it initially caused improper engraving.

Methods for Positioning a Design on a Shirt

There are several ways to accurately position a design on a shirt:

Using a Projector

1. Project the Design: Use a low-cost projector to project the design onto the shirt.

2. Mark the Position: Mark the design's position with small pieces of white sticker paper from Amazon, or tape.

3. Measure the Size: Measure the size of the design.

Without a Projector

1. Estimate Size: Estimate the design's size.

2. Measure: Use a ruler to measure one dimension.

3. Resize the Design: Resize the design to fit the different dimensions of various shirts for the best result.

Alignment

1. Fold the Shirt: Once you determine the design size, fold the shirt in half.

2. Mark the Center: Mark the center with two pieces of tape or sticker paper to help with alignment later.

IMPORTANT: Be sure to resize the design in xTools Creative Space so the design fits your shirt correctly.

The next step is to engrave the screens for our multi-color design using the D1 Pro. This process involves separating the design into individual colors, aligning and scaling each color accurately, and then engraving the screens. Follow the steps below to ensure precise engraving and proper setup for screen printing.

1. Prepare Screens: Since the design uses three colors, you need to engrave three separate screens—one for each color.

2. Separate Colors: In the file, colors are combined. Click and drag to separate each color for individual engraving. Repeat this for all colors.

3. Align and Scale: Ensure the origin is aligned and that the design is properly scaled and positioned within the green engravable area on your screen.

4. Flip and Orient: Verify that the design is flipped horizontally and oriented correctly for your shirt.

5. Start Engraving: Begin the engraving process. The time required will vary based on shirt size; mine took just over an hour.

6. Watch Tutorial: While the D1 Pro is engraving, watch this YouTube video on screen printing with the xTools Screen Printer, as the next steps can be technical.

1. Install Engraved Screens: Remove your engraved screens from the laser cutter and securely attach one to the Screen Printer.

2. Prepare Shirt and Plate: Place a sticky mat onto the wooden plate to prevent the shirt from shifting during the printing process. Position your shirt on top of the sticky mat. Using the sticky mat is essential when printing multiple colors to ensure the shirt stays in place between each print.

3. Align the Shirt: Use the three knobs at the bottom of the plate to adjust and line up the shirt accurately. Align the shirt with the center marked by tape for precise placement.

4. Apply First Color: Flood the screen with the first color of ink at a 45-degree angle. Add more ink at the bottom of the design to ensure even coverage.

5. Print and Dry: Lower the screen onto the shirt and pull the squeegee across the design to deposit the ink. Lift the screen and allow the ink to dry using a hair dryer, heat gun, or heat press. Repeat steps 3, 4, and 5 for each additional screen and color.

6. Finish: Carefully remove the shirt from the plate and let it dry completely.