Evaluating the quality of a direct-emulsion stencil before it is on press is a difficult task. Pinholes and edge defects might be uncovered with illumination and magnification, but overall stencil quality and flatness are impossible to measure. After many months of research, a test has been established that can evaluate the relationship between the emulsion and the mesh. We call this relationship the Rz value, and it may provide the screen printing industry with a concrete method of judging the quality of directemulsion stencils before printing.