For experienced printers, mesh selection is no longer about mesh count alone. It’s about how geometry, surface energy, and thread construction interact with modern inks, emulsions, and production demands.

SAATI Hi-Dro® mesh was developed specifically to address these variables in garment printing, with a focus on water-based inks, abrasive systems, and long production runs.

This article breaks down exactly what makes Hi-Dro different — and why those differences matter on press.

High Modulus, Low Elongation: Stability First

Hi-Dro is a high modulus, low elongation monofilament polyester fabric .

In practical terms, this means:

• Less stretch during tensioning
• Better tension stability over time
• Reduced image distortion during long print runs

For printers chasing registration consistency, especially across multiple colours or extended runs, low elongation directly supports:

Reduced need for mid-run retensioning

Cleaner edges

Predictable stencil behaviour

Thinner Thread Diameters — Without Changing Mesh Count

One of the defining design choices in Hi-Dro is that it maintains standard mesh counts while using thinner thread diameters .

Why this matters:

• Thinner threads = larger, more precise mesh openings
• Increased open area at the same mesh count
• Improved ink flow without jumping to a lower mesh

For example, Hi-Dro fabrics show:

• Open area values up to 61% depending on mesh
• Consistent mesh openings down to 53 µm in higher mesh counts

This allows printers to:

Avoid unnecessary compromises between coverage and detail

Maintain image resolution

Improve deposit efficiency

Optimised Mesh Geometry = Predictable Ink Transfer

Hi-Dro is manufactured with an improved production process that delivers:

• Optimised mesh geometry
• Precise and consistent mesh openings across the fabric

On press, this translates to:

• More uniform ink release
• Reduced turbulence during the squeegee stroke
• Higher fidelity to the film positive — particularly in fine detail and halftones

Microscopic comparisons in the TDS show that standard meshes allow threads to partially block openings, while Hi-Dro maintains clean, open structures that replicate the film image more accurately .

Plasma Surface Treatment: No Degreasing Required

Hi-Dro uses a long-lasting plasma surface treatment, not a temporary chemical coating .

This has several technical advantages:

• No degreasing pretreatment required before stencil coating
• Consistent surface energy across the mesh
• Improved stencil adhesion from first coat to reclaim

Because the treatment is plasma-based, it:

Supports longer stencil life on press

Stencil Performance and Emulsion Compatibility

WHi-Dro is listed as safe under exposure with all emulsion types, including:

• Photopolymer
• Dual-cure
• Diazo
• Capillary films

Combined with superior stencil adhesion, this results in:

• Less stencil breakdown during printing
• Fewer pinholes and edge failures
• Longer production runs without touch-ups

For high-volume or abrasive ink systems, this stability directly reduces downtime.

Designed for Water-Based — Proven Under Abrasion

Although designed to optimise water-based ink printing, Hi-Dro is also rated as:

• Excellent for abrasive printing conditions
• Suitable for inks and pastes that accelerate mesh wear

This makes it a strong candidate for shops running:

Water-based whites

High-solids systems

Frequent reclaim cycles

Coverage on Dark Garments Without Over-Depositing

Improved ink flow and precise openings allow Hi-Dro to deliver:

• Excellent coverage on dark garments
• Without relying on excessive ink volume

The result is:

Cleaner prints

Better hand feel control

Reduced need for extra passes

Where to Source Hi-Dro Mesh

For printers looking to upgrade stencil performance, improve ink flow, and introduce more control into their screenmaking process, Hi-Dro represents a technical step forward — not just a material change.

If you’re considering re-meshing or want to explore whether Hi-Dro is the right fit for your production environment, sourcing the correct mesh and specifications is critical.

Saati Hi-Dro mesh is exclusively available at Jones Brothers, with local support to help match mesh selection to your inks, emulsions, and printing conditions.