Wearable electronics and flexible circuits are transforming how we integrate technology into everyday life, opening the door to smart textiles, fitness trackers, and real-time health monitoring. Imagine EKG (electrocardiogram) and EMG (electromyography) sensors printed directly onto fabric, seamlessly embedded into clothing for biometric tracking and interactive wearables. Screen-printing conductive ink onto fabric is a game-changing technique that makes these innovations possible, offering a versatile, scalable way to bring electronics to textiles.
At NovaCentrix, we regularly speak with customers who are exploring manual screen printing for prototyping and need guidance on the best materials and techniques to get started. A few years ago, we created this three-part video series to walk through the entire process—from preparation to printing and cleanup—using Metalon® HPS-FG32 silver conductive ink (we would recommend HPS-FG57B if we made the video today), designed for wearables and textile-based electronics. While technology continues to evolve, the fundamentals of screen printing conductive ink remain the same, making this guide a valuable resource for researchers, engineers, and hobbyists looking to create high-quality, durable conductive prints for next-generation smart fabrics.
Part 1: Preparing Your Materials
👉 Watch Part 1: How to Prepare for Conductive Ink Screen Printing
Before starting the printing process, proper preparation is key to ensuring clean, uniform conductive traces. In Part 1, Dr Vahid Akhavan, goes through the essential tools and materials needed for successful printing.
Key Preparation Steps:
✔ Choose the right fabric – Cotton is ideal due to its strong wetting characteristics with Metalon® HPS-FG32 ink (new recommendation would be HPS-FG57B).
✔ Gather essential tools – A stainless steel wire screen and a screen printing table, soft squeegee, spatula (or tongue depressors), and cleaning supplies (IPA, soapy water, paper towels, waste container).
✔ Iron the fabric before printing – Removing wrinkles ensures even ink application and better screen contact.
✔ Prepare the ink properly – Mix the ink thoroughly using a spatula before applying it to the screen.
Proper preparation helps ensure smooth, consistent prints that adhere well to the fabric.
Part 2: Printing the Conductive Pattern
👉 Watch Part 2: How to Print Conductive Ink onto Fabric
In Part 2, Dr. Vahid Akhavan demonstrates the actual screen-printing process, focusing on techniques that help achieve precise and uniform conductive ink application.
Key Printing Steps:
✔ Flood the screen first – Pre-wetting the screen with ink ensures a smooth and uniform transfer.
✔ Use enough ink— but not too much – The ink should fully cover the pattern without oversaturating the fabric.
✔ Apply uniform pressure with a squeegee – Use both hands to apply firm, even pressure to push the ink through the mesh.
✔ Use multiple passes – At least two to three passes ensure the fabric absorbs enough conductive ink for reliable traces.
✔ Keep the screen moist between prints – Prevent clogging by keeping the screen covered or misted between uses.
By following these techniques, you’ll achieve high-quality conductive traces that can be used in wearable electronics, sensors, and other flexible applications.
Part 3: Proper Screen Cleaning for Longevity
👉 Watch Part 3: How to Clean a Conductive Ink Screen-Printing Screen
Once the printing is complete, proper cleanup is essential to maintain the screen’s usability and prevent clogging or damage. In Part 3, Dr. Vahid Akhavan walks through the best practices for cleaning conductive ink from the screen, ensuring it’s ready for future use.
Key Cleanup Steps:
✔ Reclaim excess ink – Conductive ink, especially silver-based inks, can be expensive. Use a tongue depressor (or spatula) to collect unused ink and return it to the supply bottle if desired.
✔ Wear gloves – Silver ink can stain the skin, so gloves help prevent unwanted contact.
✔ Start with Isopropyl Alcohol (IPA) – Flooding the screen with IPA helps loosen and dissolve the ink particles. Leave it to sit for a few minutes to make washing easier.
✔ Do NOT use water first – Even though the ink is water-based, applying water before removing excess silver can clog the screen openings. Always start with IPA first.
✔ Clean the squeegee – Wipe it with IPA-soaked paper towels to remove excess ink buildup.
✔ Follow up with soapy water – Once the ink is mostly removed, wash the screen with soapy water to eliminate remaining residue.
✔ Finish with clean water rinse – A final rinse with clean water ensures that no IPA or soap residue remains.
✔ Let the screen dry completely – Once dry, the screen is ready for the next printing session.
Proper cleaning prolongs the life of the screen and maintains print quality, preventing costly replacements.
Final Thoughts & Getting Started
By mastering proper preparation, printing techniques, and cleanup, you can successfully screen-print high-quality conductive patterns on fabric for wearable electronics, sensors, and other flexible circuit applications.
Ready to Try It Yourself?
🔹 Metalon® Conductive Inks: Explore Here
🔹 Screen Printing Kit: Get Yours Now
Leave us a comment or get in touch if you want to learn more.
Rudy is the VP of Business and Applications Development at NovaCentrix. Rudy joined NovaCentrix in 2017 and has since held roles ranging from Applications Engineer to Technical Lead and Director of Sales (at PulseForge). Currently, he focuses on business and applications development to align with NovaCentrix’s customer needs. Before NovaCentrix, Rudy was the Lead Scientist at Applied Novel Devices Inc., where he worked on ultra-thin solar cells for the Department of Defense. As a post-doctoral researcher at the University of Texas at Austin, he led efforts at the Microelectronics Research Center on 2D material growth. Rudy holds a PhD in Physics from the University of North Carolina at Chapel Hill and an MS in Physics from IIT Bombay. With over 20 years of materials science research experience and more than 30 technical publications, Rudy combines technical expertise and business acumen to support NovaCentrix’s customers.