Further, since most people use computers to "stencilize" their artwork I didn’t see any discussion about how to design strong, durable stencils that will withstand multiple printings.

Documentary filmmaker Neal Hutcheson and I traded services to make this 6 part video on stencil screen printing, a tedious but very low-cost way of mass producing t shirts. This is how I make all my shirts, from the Super Berry Bun Buns to the Echoboy t shirt series.

So grab a tasty beverage, pull up a chair and come with me on a journey to the wonderful world of stencil screen printing (and watch for special appearance by my kitty cat Jack Jack).

How To Stencil Screen Print T Shirts (1-2)
1) Image to Stencil
2) Prepping to Cut Stencil

How To Stencil Screen Print T Shirts (3-4)
3) Cutting Stencils
4) Prepping the Shirts

How To Stencil Screen Print T Shirts (5-6)
5) Printing with Screen and Stencil
6) Clean Up/Setting the Ink

Bo Muller-Moore’s iconic “Eat More Kale” t shirt is a classic:

And it’s pure stencil goodness! Yum! As a stencil printing dork I wrote him an email and then put together some quick interview questions that I thought would interest other potential printers.

1) GarrettShirts>> why/how did you learn to use stencils instead of other screen printing methods?
EatMoreKale>> simplicity, eco friendly and storage (and design ideas, my ideas are simple enough and one color only always.)

2) GS>> I understand you do all the printing, ironing and shipping of your tshirts. What techniques have you found for speeding up these processes?
EMK>> I bought a $400 heat press that heat sets 3 shirts at a time. @350degrees for @4 minutes with mine. (I got this back in the winter and have not updated my site yet, whoops) A good fan or ventilation is a must.

3) GS>> what kind of ink do you use?
EMK>> spectrachem water based jet black.

4) GS>> roughly how much time per week do you spend on tshirts?
EMK>> 8-12 hours

5) GS>> do you sell more shirts online or in person?
EMK>> Online… my website has been wonderful. festivals and craft shows are OK, but there are too many variables. (the fun festivals are a blast, when people like your shit)

6) GS>> would you advise tshirt printing newbies to go for physical sales first or try and do online sales?
EMK>> Both, that said, I think a hip, smart computer savy person could use all the tricks of the trade and do quite well online. (websites, youtube, blogs, bla bla bla bla) ( I’m not very good at that sort of thing, just as good as I have to be.) My bumper stickers have been the best move for me and my micro biz. Instead of business cards, I give stickers away by the 1000′s and folks wind up at my site.

7) GS>> what’s your favorite part about printing shirts?
EMK>> I’ve always dug t-shirts, but was not an “artist”. Now to be called an “artist” and to dig my own t-shirts makes me very happy. If you like what your doing, you can’t go wrong right?

Let me make it very clear. I’m not getting rich doing this. If I wasn’t making a living as a foster parent I would not have the capital and time to help keep my micro biz rolling. It pays for itself and a little more, but does not create wealth!

So, big thanks to Bo for the interview! You can check out an interview he did with Vermont’s Seven Days – an independent newspaper. Read Kale for Sale to learn a bit more about the business side and history of his shirts.

And of course you should visit EatMoreKale.com to check out his other designs.