What Is the Digital Squeegee?
The hybrid printing technology that combines screen printing durability with digital inkjet quality — in a single pass.
How the Digital Squeegee Works
The Digital Squeegee revolutionizes apparel printing by combining two proven technologies in a single automated process. Unlike traditional methods that require separate workflows, this hybrid system completes the entire print in one pass through the machine.
Step 1: Screen Print the Base
A white plastisol base coat is screen printed onto the garment using traditional screen printing techniques on an automatic press. This creates a smooth, bright white foundation that ensures vibrant color reproduction on any garment color, including black and dark fabrics. The plastisol base is applied through a precision mesh screen, creating a uniform layer that bonds permanently to the fabric.
Step 2: Digital CMYK Overprint
While the plastisol base is still wet, 16 precision inkjet heads print full-color CMYK artwork directly onto the base at 300 DPI resolution. The Digital Squeegee uses GOTS-certified water-based inks that are vegan, PVC-free, and contain no heavy metals or phthalates. The digital heads are mounted directly on the screen printing press, allowing the entire process to happen in a single pass without removing the garment from the platen.
Step 3: Cure
The garment passes through a conveyor dryer where both the plastisol base and the water-based digital inks cure simultaneously at controlled temperature. The heat causes a chemical bond between the two ink layers and the fabric, creating a permanently bonded, durable print that withstands 50+ washes. The entire process from blank garment to finished print takes less than 60 seconds per piece.
Digital Squeegee Technical Specifications
| Feature | Specification |
|---|---|
| Print Heads | 16 advanced digital inkjet heads |
| Resolution | 300 DPI |
| Color System | CMYK + White base |
| Speed | Up to 600 pieces per hour |
| Ink Type | GOTS-certified organic water-based inks (vegan, PVC-free) |
| Wash Durability | 50+ washes |
| Fabric Compatibility | Cotton, polyester, blends, fleece |
| Minimum Order | 72 pieces |
| Manufacturer | M&R (Machines & Robots) |
History of the Digital Squeegee
M&R, a leading manufacturer of screen printing equipment, developed the Digital Squeegee technology to bridge the gap between traditional screen printing durability and the unlimited color capabilities of digital printing. The system was designed to address a critical need: hybrid printing for custom apparel that delivers photorealistic, full-color designs on garments while maintaining the wash durability and production speed that screen printing is known for.
Print Hybrid was among the first screen printing shops in the United States to adopt the Digital Squeegee. With 22+ years of experience in the custom apparel industry, Print Hybrid recognized the revolutionary potential of this hybrid technology and invested early in the equipment. This early adoption gave Print Hybrid a competitive edge in serving customers who needed complex, full-color designs with professional durability.
Today, Print Hybrid operates TWO Digital Squeegee presses — making it the home of the "Double Digital Squeegee." With dual machines running simultaneously, Print Hybrid can produce up to 5,000 hybrid printed garments in an 8-hour production shift. This dual-machine capability is rare in the United States, with only a handful of shops nationwide operating multiple Digital Squeegee systems.
Digital Squeegee vs Other Printing Methods
Understanding how the Digital Squeegee compares to other apparel printing technologies helps you choose the right method for your project.
| Feature | Digital Squeegee (Hybrid) | DTG | DTF | Traditional Screen |
|---|---|---|---|---|
| Resolution | 300 DPI | 1200 DPI | 720 DPI | 50-60 DPI |
| Colors | Unlimited | Unlimited | Unlimited | 1-12 per screen |
| Min Order | 72 pieces | 1 piece | 1 piece | 48 pieces |
| Durability | 50+ washes | 10-20 washes | 50+ washes | 50+ washes |
| Speed | 600/hr | 30-50/hr | Varies | 400-800/hr |
| Fabrics | All types | Cotton only | All types | Cotton, blends |
| Ink Type | Water-based GOTS | Water-based | Adhesive powder | Plastisol |
| Best For | 72+ pcs, complex art | 1-50 pcs, cotton | 1-71 pcs, any fabric | 48+ pcs, simple designs |
Digital Squeegee FAQ
M&R (Machines & Robots), a leading manufacturer of screen printing equipment. The Digital Squeegee is their hybrid printing solution that integrates digital inkjet technology into the screen printing workflow. M&R is known for producing industrial-grade automatic screen printing presses used by print shops worldwide.
DTG (Direct-to-Garment) prints directly onto fabric without a screen-printed base. The Digital Squeegee prints onto a wet plastisol base, providing far superior wash durability (50+ washes vs 10-20 washes), fabric versatility (works on polyester and blends, not just cotton), and production speed (600 pieces/hour vs 30-50 pieces/hour). The plastisol base also creates more vibrant colors on dark garments.
Yes. The screen-printed white plastisol base creates a bright foundation for the digital CMYK layer, enabling vibrant colors on any garment color including black, navy, and dark heather. The white base is opaque and completely blocks the underlying garment color, ensuring that your artwork appears exactly as designed regardless of the shirt color.
Two. Print Hybrid is the home of the "Double Digital Squeegee" — one of very few shops in the US with dual machines. This enables up to 5,000 hybrid prints per 8-hour shift. Having two machines also provides redundancy and backup capacity, ensuring we can meet tight deadlines even during peak production seasons.
Yes. The Digital Squeegee uses GOTS-certified organic, vegan, water-based inks free of PVC, phthalates, lead, heavy metals, and ozone-depleting chemicals. Cleanup requires only water, eliminating the need for chemical solvents. While the plastisol base coat is still petroleum-based, the majority of the printed area uses eco-friendly water-based inks, making hybrid printing significantly more environmentally responsible than traditional all-plastisol screen printing.
72 pieces. The Digital Squeegee is optimized for medium to large production runs where the setup time and press configuration are justified by the volume. For smaller orders (1-71 pieces), Print Hybrid offers DTF digital printing with no minimum order quantity. DTF achieves similar quality and durability while being cost-effective for low-quantity projects.
