Ethan Clarke
Screen printing on plastic is a common method of decorating plastic packaging films and containers. It is a secondary process used to improve the appearance of plastic products by transferring visual information or images onto them. This technique is used on a variety of plastic products, including those with different surface textures, hardnesses, and shapes. When screen printing on plastic, it is important to use a higher mesh count, such as 280 or higher, to prevent the ink from falling through and ruining the print. Additionally, the plastic surface may need to be processed before printing to improve the adhesion of the ink.
| Characteristics | Values |
|---|---|
| Printing methods | Gravure printing, flexographic printing, screen printing, anti-counterfeiting printing, jet printing, transfer printing, laser etching, pad printing, dry offset printing |
| Printing on different plastic types | Sheet and plane plastics use plain screen printing, cambered surfaces use curved silk screen printing, and abnormally-shaped plastics use indirect screen printing |
| Plastic properties | Simple dyeability, weak solarized colorfastness |
| Ink properties | Plastic items contain a polar substance in their molecular structure, which is corrosion-resistant to most acids and alkalis and insoluble in common solvents at room temperature. Additives such as antioxidants and stabilizers are added to the ink to reduce affinity with the plastic surface and slow down drying |
| Ink application | For air-dry inks, use a mesh count of 280 or higher to prevent ink from falling through |
| Surface preparation | The plastic surface must be cleaned and cleared of dust, lint, or scratches. It may need to be processed to improve ink adhesion |
| Equipment | A screen printing press is typically used, but additional supplies may be needed depending on the specific application |
| Storage | Items printed with air-dry inks require adequate space for drying |
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What You'll Learn
Printing methods: screen, gravure, flexographic, anti-counterfeiting, jet, transfer, etc
Screen printing is a popular method for printing promotional materials and packaging that require a tactile, visually impactful presentation. It is one of the most commonly used printing methods, alongside offset (lithography), flexography (often shortened to flexo or flexographic printing), thermal transfer, digital, dye-sublimation, gravure, 3D, letterpress, rotogravure, pad, electrostatic, inkjet, laser, and thermography.
Flexographic printing is a key printing technique in the packaging industry, specialising in continuous roll-to-roll printing. It uses flexible, photopolymer plates on rotating cylinders for ink transfer to a variety of substrates. It is known for its efficiency and adaptability, and is used for printing on paper, plastic film, corrugated cardboard, and metallic surfaces. Flexography is commonly used for printing flexible materials such as packaging, labels, and plastics. It is also suitable for printing on tissue paper, napkins, shopping bags, disposable plates and cups, showcasing its versatility. Water-based, UV-based, and alcohol-based inks are used in flexography.
Gravure printing is another high-quality printing method that is commonly used for printing magazines, catalogues, packaging, and other high-end printed materials. It uses a rotary printing press with recessed cells of varying depth and size that hold ink and transfer it onto the paper or other materials being printed. Gravure printing produces very high-quality prints with sharp, crisp images and vibrant colours. It is especially suited for printing on materials with a smooth surface, such as coated paper or film, and is often used for printing large quantities.
Digital printing is a versatile method that can be done in various ways. Inkjet printing, for example, can print on a wide range of substrates such as paper, plastic, canvas, or even doors and floor tiles. Inkjet printing is used a lot for posters and signage. Digital printing is ideal for short runs and customisable packaging and variable data projects, especially effective for flexible and folding carton packaging. However, its cost per unit may rise substantially for larger quantities compared to other methods.
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Plastic types: sheet, plane, cambered surface, abnormity
Screen printing is a common technique used to print on plastic products. It is a secondary process used to improve the appearance of plastic products by transferring visual information or images onto a plastic product using a printing screen.
- Sheet and plane plastics: Use plain screen printing, also known as flat screen printing, on flat surfaces.
- Cambered surface: Use curved silk screen printing on curved surfaces. This technique can also be applied to spherical or unevenly shaped objects.
- Abnormalities: Use indirect screen printing for irregular products.
The specific printing method used depends on the shape of the plastic product. For example, polycarbonate sheets are suitable for screen printing, whereas polycarbonate films are more straightforward for digital printing.
The plastic surface must be processed before printing to improve ink adhesion. Plastics contain a polar substance in their molecular structure, which is corrosion-resistant to most acids and alkalis. Additives such as antioxidants and stabilizers are added to the ink to reduce the affinity between the plastic surface and the ink.
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Ink types: air-dry, plastisol
Air-dry inks may need to be heat-set and do not simply air-dry. They fall into two categories: non-oxidizers and oxidizers. Non-oxidizers dry only by the evaporation of solvents, without any chemical process involved. Oxidizing inks, on the other hand, contain solvents that evaporate and contain chemicals that dry by oxidation. Non-oxidizing inks are more popular today as they are easier to work with.
Plastisol inks, which are limited to textiles, will never dry when exposed to air and must be cured with heat. They are made up of PVC resin and plasticizer. The recommended temperature for curing plastisol inks is between 320 to 330 degrees Fahrenheit, and they start to become dry to the touch between 180 to 250 degrees Fahrenheit. Curing plastisol inks shortly after printing is important, as delaying the process may cause the plasticizer to leach out of the ink and into the garment.
There are various methods for curing plastisol inks. While a belt dryer is the machine of choice for curing large quantities, home printers often use a flash cure unit, space heaters, heat guns, or blow dryers.
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Surface preparation: cleaning, scratch removal
To prepare the surface of a plastic item for screen printing, it is important to start with a clean surface. This can be done by wiping the surface with a solvent or a mild detergent solution to remove any dirt, dust, or oils that may interfere with the printing process. It is also important to ensure that the plastic surface is free of any scratches or other imperfections that could affect the quality of the print.
If the plastic surface has scratches or other damage, there are several methods that can be used to repair the surface. One method is to use fine-grit sandpaper to gently sand the scratched area, being careful not to create additional scratches or damage to the surrounding area. The sandpaper should be used in a circular motion, and the area should be sanded until the scratch is no longer visible.
Another method for removing scratches from the plastic surface is to use a plastic polish or compound. This is a liquid or paste that is applied to the scratched area and then buffed out using a soft cloth or pad. This method can help to fill in and smooth out the scratched area, creating a smooth surface for printing.
In some cases, it may be necessary to use a combination of the above methods to achieve the desired results. It is important to test any repair methods on a small, inconspicuous area of the plastic surface before proceeding with the actual repair to ensure that the method is effective and does not cause any further damage.
Once the plastic surface is clean and free of scratches, it may also be necessary to treat the surface with a primer or adhesive promoter. This will help to improve the adhesion of the ink to the plastic surface, resulting in a higher-quality print. The specific treatment method will depend on the type of plastic and the ink being used, so it is important to consult with a professional or refer to the manufacturer's recommendations for the best results.
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Drying and curing: drying racks, storage
Drying racks are an essential component of the screen-printing process. They provide a space-efficient solution for printers to dry multiple screens at once. Screens need to be dried and stored during the exposing and reclaiming process, and drying racks offer a dedicated space for this. Racks come in various sizes, from small countertop designs to large floor-standing units with rollers, ensuring printers can choose the most suitable option for their workspace.
These racks also facilitate effective transport and storage during printing. They can hold screens at various stages of the printing process and accommodate tools like squeegees. Proper drying and curing are critical to ensuring the durability and quality of prints. Insufficient curing can lead to issues with adhesion, impacting the final product's longevity and appearance.
Printers should consider their workspace and the number of screens they typically use simultaneously when selecting a drying rack. For those with limited space, countertop racks offer a convenient solution without occupying excessive areas. Conversely, larger operations with more screens might favour the higher capacity provided by floor-standing racks.
Drying racks are specifically designed to optimise the drying process, enhancing airflow around screens to accelerate drying times. This functionality ensures printers can efficiently rotate screens, improving productivity by reducing downtime between prints. Proper drying and storage of screens also contribute to a well-organised and safe working environment, reducing clutter and potential hazards.
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Frequently asked questions
Screen printing is a secondary process used to transfer images or information onto plastic products.
There are various methods of screen printing on plastic, including sheet and plane plastic, curved silk screen printing, indirect screen printing, gravure printing, flexographic printing, anti-counterfeiting printing, jet printing, and transfer printing.
Screen printing on plastic is a great way to expand your business offerings and attract new customers. It is also easier to fix mistakes on plastic surfaces compared to fabric.
Air-dry inks are commonly used for screen printing on plastic. It is recommended to use a higher mesh count, 280 or higher, to prevent the ink from falling through and ruining the print.
Before printing, ensure the plastic surface is clean and free of dust, lint, or scratches. Then, choose the appropriate mesh count and printing method based on the type of plastic and its surface texture, hardness, and shape. Finally, apply the ink and allow it to dry completely.
