"He who marches out of step hears another drum." ~ Ken Kesey
Maybe I'll try Aquasol + permanent hardener and see what happens first, don't want to break my "one emulsion to rule them all" setup. I know for a fact the plastisol screens will crack at some point at the EOM we coat them + the gauntlet putting incessant sq pressure on them, but maybe a sq side face coat will help and plasti screens can be bottom taped in any case. This is all spots, easy stuff so yeah, would prefer statics but also would prefer to keep using our pin lock on these for setup, this is where a tri-lock excels. Have you tried using a press wash like franmar's color change on your sim pro screens instead of putting them in the booth? It would take more time to tear down but it's super gentle, might not cause the swelling issues though you do need to "rinse" it with a damp rag. Just hit it immediately with a dry rag or compressed air. Or is the swelling just from the ink?