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Water-Based vs Plastisol Screenprinting: What’s the Difference?
If you are ordering custom t-shirts, one of the biggest decisions happens before the shirts are even printed.
It comes down to the ink.
Two of the most common methods are water-based screenprinting and plastisol screenprinting. While they can produce similar-looking designs, they perform very differently once worn.
Understanding those differences can help you choose the right option for your shirts.
Feb 28, 2026
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Compare water-based and plastisol screenprinting. Learn how each method feels, wears, and performs to choose the best option for custom t-shirts.
What Is Water-Based Screenprinting?
Water-based screenprinting uses ink that soaks into the fabric rather than sitting on top of it.
Because of that, the print feels soft, lightweight, and breathable.
At Sunday Cool, our Super-Soft Ink is a water-based screenprinting method designed to keep the shirt feeling like a shirt, even after it is printed.
This method is ideal when comfort matters, especially for shirts that will be worn often.
What Is Plastisol Screenprinting?
Plastisol screenprinting uses a thicker ink that sits on top of the fabric.
This creates a more structured, layered print that is easy to see and feel.
It is often used for bold graphics and high-opacity prints, especially on darker garments.
However, because the ink sits on top of the shirt, it can feel heavier and less breathable compared to water-based printing.
The Biggest Difference: How It Feels
This is where the difference becomes obvious.
Water-based screenprinting creates a print that feels soft and natural, almost like it is part of the fabric.
Plastisol screenprinting creates a thicker layer on top of the shirt. That can make the print feel stiff, especially in larger designs or designs with heavy ink coverage.
Over time, plastisol prints can also feel more noticeable with repeated wear.
If you have ever worn a shirt where the design feels like a patch sitting on top, that is typically plastisol.
Breathability and Everyday Wear
Comfort is not just about how a shirt feels at first. It is about how it wears throughout the day.
Because water-based ink blends into the fabric, it allows the shirt to remain breathable.
Plastisol, on the other hand, can trap heat where the design sits. On larger prints, this can make the shirt feel warmer and less comfortable over time.
For shirts that are meant to be worn often, especially in warm environments, this difference matters.
How They Age Over Time
Both printing methods are durable, but they age differently.
Plastisol prints tend to hold their shape, but over time they can crack or peel, especially if the print is thick.
Water-based prints age more naturally. Because the ink is part of the fabric, it softens with the shirt rather than separating from it.
Many people prefer this worn-in look because it keeps the shirt feeling comfortable even after repeated washes.
Which One Should You Choose?
Both methods have their place, but for most custom t-shirts, water-based screenprinting is the better choice.
If your goal is to create something that people will actually wear again and again, comfort matters.
Water-based printing delivers:
a softer feel
better breathability
a more natural look over time
Plastisol can still work for very bold or highly saturated designs, but for everyday wear, it is often not the preferred option.
Why We Focus on Water-Based Printing
At Sunday Cool, we have spent years refining what makes a great custom t-shirt.
One of the biggest factors is how it feels.
That is why we use water-based screenprinting through our Super-Soft Ink. It allows us to create shirts that look great, feel comfortable, and hold up over time.
Because in the end, the best shirt is the one people keep wearing.
Beyond Ink: Specialty Finishes That Stand Out
In addition to our Super-Soft Ink, we also offer a range of Specialty Inks that create unique, interactive designs.
These specialty options can add another layer of creativity while still maintaining the comfort and quality of our printing process.
Ready to Get Started?
If you are looking for custom t-shirts with a soft, high-quality print, we are here to help.
👉 Ready to Get Started? Start your custom order HERE
People Also Ask
What is the difference between water-based and plastisol screenprinting?
Water-based screenprinting soaks into the fabric, creating a soft, breathable print. Plastisol screenprinting sits on top of the fabric, resulting in a thicker, more noticeable layer.
Which screenprinting method is softer?
Water-based screenprinting is softer because the ink blends into the fabric instead of forming a layer on top.
Does plastisol ink crack over time?
Plastisol ink can crack or peel over time, especially with heavier prints. Water-based prints tend to wear more naturally with the fabric.
Which is better for custom t-shirts?
For most custom t-shirts, water-based screenprinting is the better choice because it provides a softer feel, better breathability, and more comfortable long-term wear.
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"Your Logo Here" has never looked so good - let us guide the way.
Both tees are great—it just depends on the look you’re going for.
If your vibe is clean and classic, the Signature Super-Soft Tee is your go-to. If you're leaning relaxed, bold, and a little oversized, the Oversize Boxy Tee is calling your name.
Ready to Start Your Next Order?
If you are planning shirts for camp, church, or any summer event, this is a solid place to start.
👉 Ready to Get Started? Start your custom order HERE
Retro-inspired designs are having a moment, and they fit camp perfectly.
Think warm tones, vintage fonts, and throwback layouts that feel fun without trying too hard. These are the kinds of shirts students actually keep wearing.
For many churches, the most meaningful shirts are rooted in Scripture.
Whether it is a full verse or a short phrase, these designs carry the message of camp beyond the week itself. The key is keeping it readable and wearable.
Some of the most worn designs are the simplest ones. Subtle graphics, clean layouts, and intentional spacing often lead to shirts that feel more versatile.
Water based ink is the point between here and heaven. Paired with our Super Soft Tees, the nonexistent feel of our Water based ink is magical and sure to be the talk of the town with you and your group.
Here at Sunday Cool, we inventory 66 different ink colors! These colors were curated based off of customer popularity and diversity. You can view those stock ink colors below.
During the ordering process, you can reference this page to view all of our stocked ink colors. You’ll also be served up a choice of our stock inks when you submit your Art Request Form.
But what if none of the Sunday Cool Stock Inks match my design or logo? Nothing to fear! We can Pantone Match your ink to whatever code you’re needing to a 90% accuracy.
There are a few requirements to qualify for a Pantone Match on your project:
Stick to our Super Soft Signature line of apparel.
The garment color you choose must discharge vibrantly, not vintage. If you need help determining which of our inventory items discharge at which rates, check out our blog post entitled Waterbased Print Results.
Your order must include 144 units or more.
Additionally, we charge $25/match! This means if we need to match 2 ink colors to a specific code, it’ll be a $50 charge.
But how do I know which code to send you? Great question! Your organization might have a branding guide including all relevant codes and colors that set your group apart. OR you could send in your logo and ask us! Our talented Art Staff can color match the logo and tell you the code! We work often in the Pantone and HEX libraries!
As always, if you have any questions regarding our inks & matching guides, please reach out to a Sunday Cool Concierge member using the dot icon in the corner of your screen.
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