Abstract: The invention relates to methods of manufacturing a printing screen that is operable for use in a rotary screen printing process, wherein a metallic sheet having a generally cylindrical shape is positioned adjacent a laser. The metallic sheet is rotated about its longitudinal axis, and the laser is moved along a path parallel to the longitudinal axis. The laser directs focused radiation to the metallic sheet such that holes are formed therethrough. Portions of the metallic sheet are vaporized, which leaves the metallic sheet substantially free of slag. In this regard, the metallic sheet can be formed from a single layer having at least one exposed surface, such that the focused radiation contacts only the metallic sheet.