How to Screen Print on a Trucker Hat using Vinyl

1. Artwork

For the artwork you want to go with a simple one solid color design keeping it to 5 inches wide and 3 inches tall.

Canva Magic Media: I used Canva Magic Media to generate the graphics.
Adobe Illustrator: Then I used Adobe Illustrator to vectorize the graphics using image trace.

2. Making the Screen Using Vinyl

I like to use a 110 mesh screen. Depending on the ink you're using you can go up or down from there.

Cut the Vinyl: Mirror the graphic and send it over to your vinyl cutter to cut out the design in the sticker vinyl.
Weed Out the Design: Use the weeding tool to carefully weed out the design so you get all the details.
Transfer Tape: Apply transfer tape on the sticker vinyl and use your squeegee to press them together.
Peel The Backing: Peel off the sticker vinyl backing, leaving the sticker vinyl on the transfer tape.
Place The Transfer: Hold the screen over the transfer where you want the design to go. It should land on the top center of the screen. Depending on the length of your screen press "arm" it will be closer to the top of the middle of the screen. When you're happy with the placement press the screen on the transfer and use the squeegee to press them together.
Remove the Transfer Tape: Use your squeegee to press the other side then carefully peel off the transfer tape from the corner towards the center of the design.
Tape Up The Design: Now just tape the edges of the design so the ink doesn't go through and take it over the the press.

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3. Screen Printing

Load the Hat: Load the trucker hat on the Captain Platen by following these steps.
Register the Screen: Register the screen to the Captain Platen so that the design lands where you want it to print on the Trucker Hat. You may also need to adjust the hight of the screen and the position of the Captain Platen for desired results.
Test Print: Print a test to make sure it's centered, straight and lands where you want it on the Trucker Hat.
Screen Print: Once you're happy with the test print, add some more ink to your screen and screen print your trucker hats!
Printing Process: Load the trucker hat, lower the screen , squeegee over the design (to print it), lift the screen, flood the screen (cover the design with ink), unload your hat.
Key Tip - Squeegee Technique: Hold the squeegee at a 45 degree angle to the screen and push or pull the squeegee over the design while pushing down so that the ink passes through the design and onto the trucker hat as a print of the design.

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4. Curing the Ink

The time and temperature to cure the ink is based on the type of ink (plastisol, water based, etc.) and any additives (low cure, special effects, etc.) Many plastisol inks cure at 320°F as a reference but check with the manufacturer of your ink for the specifications.

Using a Hot Air Heat Gun: Set the temperature of the hot air gun around 320°F - 350°F and go over the design one section at a time. Keep the hot air gun moving so it doesn't scorch the hat and make sure the ink gets to the required temperature to properly cure.
Using a Flash Dryer: Set the flash dryer height so it heats the ink and doesn't scorch the trucker hat. Make sure the trucker hat does not touch the flash dryer, it will easily burn. Use a temperature thermometer gun to check the ink so that it reaches the required temperature to cure properly.
Using a Conveyor Dryer: Set the temperature and belt speed to properly cure your ink. Then lay the hat on the conveyor with the print directly facing the heat source. Make sure the trucker hat does not touch the heating element or go through the dryer too slow. It was burn much more easily than a shirt would. Use a box to catch the hats on the other end.
Key Tip: Trucker hats can very sensitive to heat especially on the foam and plastic areas, so when you're curing the ink be careful to not burn these areas with long exposures to heat or direct contact to heat. Don't stack the trucker hats or touch the print before you cure the ink . You can carefully check if the ink it wet but be careful to not smudge wet ink on the trucker hat.