Vtec44 said:
What are the pros/cons of water-based ink over plastisol, minus the health issue?
Water-based ink dries in the screen, meaning you have to work faster and can get ugly blockages. On the other hand it touch dries, so it's less messy. It's harder to get a good opaque result with water-based - plastisol generally looks better on darks. Water-based has a very soft hand, which is desirable for some prints (and unimportant for others).
There's definitely pluses and minuses. I'm currently trying to find out the details of just what it takes to cure water-based ink, but my suspicion is that plastisol is easier in that regard.
(obviously I know you can cure water-based in a drying oven, and I know you can use an iron for X minutes, etc. - I'm not sure whether or not you can use a flash dryer to fully cure water-based as you can with plastisol though)