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I think the newer shirts are still screen printed, but with the trend towards dark shirts there's an additional under-layer of white, and the graphics are generally much larger and more complicated, with more colors than the older styles, which also adds layers. I'm with you, I don't like 'em; they're stiff and they don't breathe at all on a hot day. If somone could come up with a process that could print the modern graphics but were more lightweight and breathable (like "perforating" the design) they'd be onto something...
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