Disclosed embodiments relate to methods for automatically generating cutting instructions to translate a color image into a field stencil having a plurality of guideline apertures. The plurality of guideline apertures may denote the color zone boundaries in the color image, for example by being placed along the line drawing representing the color zone boundaries. Such field stencils may then allow for the reproduction of multi-color logos using a single stencil.

A method of screen printing a design on a substrate, the method comprises the steps of controlling a computer-controlled plotter to cut an outline of the design into stencil material the stencil including a perimeter. Then, registering the perimeter of the cut stencil with marks on a printing screen and securing the cut stencil to the printing screen. Then, positioning the printing screen and cut stencil on the substrate and applying ink through the printing screen and stencil onto the substrate, wherein the design is reproduced on the substrate.

A method of screen printing a design on a substrate, the method comprises the steps of controlling a computer-controlled plotter to cut an outline of the design into stencil material the stencil including a perimeter. Then, registering the perimeter of the cut stencil with marks on a printing screen and securing the cut stencil to the printing screen. Then, positioning the printing screen and cut stencil on the substrate and applying ink through the printing screen and stencil onto the substrate, wherein the design is reproduced on the substrate.

A printing screen unit comprising a mesh printing screen and a supporting frame which is attached to the printing screen, wherein the printing screen comprises a first, outer mesh which is attached to sides of the supporting frame and includes an aperture therein, and a second, inner mesh which is attached to the outer mesh, wherein threads, providing warp and weft, of the outer mesh are aligned so as to be substantially orthogonal to the sides of the supporting frame, wherein threads, providing warp and weft, of the inner mesh being aligned so as to have acute angles of between 0 degrees and 45 degrees to the respective sides of the supporting frame, wherein the printing screen is tensioned by an external tensioning assembly to a first tension when the printing screen is attached to the supporting frame, and the sides of the supporting frame are displaceable such that the sides of the supporting frame are displaced on release of the first tension by the external tensioning assembly, and the printing screen has a second, residual tension lower than the first tension.