Higher resolutions require higher mesh counts. If a stencil's halftone dot (1-50%) is not supported by at least one mesh thread, it will fall off the stencil and allow ink to print. Use a higher mesh count to hold higher dpi resolutions.
Development conditions
Use luke-warm to cool water for development with a fine spray. Hot water and excessively hard spraying may weaken a stencil. Follow proper stencil development instructions.
Too low % EOM
If a stencil's %EOM (emulsion over mesh) is too thin, high Rz may result. This will then give poor emulsion to substrate contact, allowing ink to flow under the stencil, causing a "starburst" effect.
Positive image
If the positive image contains contaminants or stray marks, they will develop as an open area on the stencil, thus allowing ink to transfer through.
