Omar Khalid
Printing on plastic has become increasingly common, especially with the rise of digital photography. There are several ways to print and transfer images onto plastic, including the use of inkjet printers, laser printers, and the dye diffusion thermal transfer (D2T2) method. Inkjet printers can be used with solvent-based inks that adhere to plastics, while laser printers use toner, a fine plastic powder that can be transferred to plastic substrates using an iron or solvents. The D2T2 method, commonly used for printing digital photos and PVC cards, involves heat-induced diffusion of dyes from a dye donor ribbon into the plastic substrate. This process offers a wide range of colours and continuous tone images. Other techniques, such as using acetone or iron-on transfers, are also explored for transferring images onto plastic surfaces.
| Characteristics | Values |
|---|---|
| Printing Method | Dye diffusion thermal transfer (D2T2) |
| Image Type | Photographic quality images, full-colour, continuous tone |
| Image Features | Security, aesthetics, brand logos |
| Image Transfer | Heat promotes diffusion of dyes from a dye donor ribbon into the plastic substrate |
| Dye Penetration | Polyesters, polyvinylchloride (PVC), polycarbonates |
| Dye Donor Ribbon | Polyethylene terephthalate (PET) coated with yellow, magenta, and cyan dye formulations |
| Back-Coat | Highly cross-linked urethane-acrylate-based polymer with lubricants and fillers |
| Dye Characteristics | High melting point, high optical strength, good affinity/solubility for binder polymers, stable to light |
| Receiver Paper/Plastic Substrate | Made of special polymer coatings that receive dyes during thermal transfer |
| Post-Transfer | Another polymer is thermally transferred on top of the printed image for protection |
| Laser Printing | Suitable for small runs, toner is a fine plastic powder melted to adhere to paper, then transferred to plastic using an iron or solvents |
| Inkjet Printing | Requires suitable ink that won't smudge on plastic, solvent-based inks provide better adhesion and scratch resistance |
| Sealant | Clear sealant or PVA glue recommended for preserving prints and allowing underlying textures to show through |
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What You'll Learn
Inkjet printing on plastic
Inkjet printing is one of the most popular methods for printing on plastic. It is a direct-to-substrate process where the artwork is created and manipulated using design software and then sent to the printer. The printer then jets the ink onto the product in tiny droplets, forming the desired image.
There are two main types of inkjet printing: UV printing and non-UV printing. UV printing uses UV inkjet ink, which is cured using UV/LED light. This type of printing requires an inkjet primer for most plastics and may also need additional pre-treatment steps, depending on the intended use. For example, drinkware that will be washed frequently may require a primer wipe and an additional pre-treatment. However, some plastics, such as Tritan Plastic, can use specialized inks that adhere without pre-treatment.
Non-UV inkjet printing, on the other hand, does not use UV light to cure the ink. This type of printing may also require pre-treatment to prepare the surface to accept the ink. One example of non-UV inkjet printing is flat-bed inkjet printing, which is often used for printing full-colour images on iPhone covers with a scratch- and water-resistant finish. These printers can be expensive, typically retailing for $1000 or more for an A4 size printer.
It is important to note that not all inkjet printers can print on plastic. Regular inkjet printers that use water-based inks will not work as the ink will not dry and will smudge. Instead, solvent-based inks are required to print on plastic. These inks are typically used on large-format inkjet printers and provide a waterproof and scratch-proof print.
Another consideration when printing on plastic is the type of plastic being used. Different plastics have different surface energies and properties, so the ink formula must be chosen carefully to ensure code compliance and long-lasting results. Ink producers offer a wide range of formulas designed for specific plastic varieties, such as PVC pipes or flexible LDPE wrap.
Overall, inkjet printing on plastic requires careful consideration of the hardware, ink formula, and pre-treatment processes to ensure successful and long-lasting results.
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Using transfer paper
Transfer paper is a great way to print designs onto plastic, fabric, and other materials. Here is a step-by-step guide on using transfer paper for your projects:
Choosing the Right Transfer Paper
First, select the appropriate transfer paper for your project. There are different types of transfer paper, such as inkjet transfer paper, opaque transfer paper, and freezer paper. Inkjet transfer paper is suitable for light-colored fabrics made from cotton or polyester. If you want to transfer onto dark fabrics or non-fabric materials like puzzles, mouse pads, or wood, choose opaque transfer paper. Freezer paper can be used with a home printer and is ideal for fabric craft projects.
Preparing the Design and Paper
Before printing, ensure your paper is not curled, bent, or stuck together. If using opaque transfer paper, cut away any blank, unprinted areas of the transfer. If your design includes text or typography, print your image in reverse to ensure it appears correctly after transfer. Remember that the image on your fabric will be a mirror image of what is on your screen, so use software to mirror your image if needed.
Applying the Transfer
After printing, do the transfer as soon as the ink is dry. For fabric transfers, preheat your fabric to remove wrinkles and moisture. Set your iron to the hottest setting and iron the fabric to prepare it for the transfer. Then, place your printed transfer, ink-side down, onto the fabric. Iron over the transfer paper for about a minute to set the ink permanently. For non-fabric materials, follow the instructions for your chosen transfer paper, as some require a heat press for application.
Post-Transfer Care
After applying the transfer, remove any blank backing from the transfer paper. For fabric items, always turn the garment inside out before washing. Wash in warm or cold water with plain detergent, and tumble dry on low heat. Avoid using bleach or detergents with whiteners or brighteners. If ironing is needed, do not iron directly on the transfer; use baking parchment or a silicone slip instead.
With these steps, you can successfully use transfer paper to decorate a variety of items with your desired designs!
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D2T2 printing
Dye diffusion thermal transfer (D2T2) printing is a process that uses heat to promote the diffusion of dyes from a dye donor ribbon directly into a plastic substrate. This method has been used for the past two decades to print photographic-quality images onto plastic substrates.
The D2T2 process offers a huge colour gamut of 16.7 million colours, allowing for continuous tone images. It can produce photographic quality images within 15-60 seconds. This process is not limited to digital photographs on plastics but can also be used to print directly onto PVC cards, such as ID cards, plastic driving licences, visitors' passes, and loyalty cards.
The dye donor ribbon consists of a thin layer of polyethylene terephthalate (PET) coated on one side with repeating panels of three dye formulations: yellow, magenta, and cyan. On the opposite side of the ribbon is a back-coat, typically made of a highly cross-linked urethane-acrylate-based polymer with added lubricants and fillers. This back-coat aids the transfer of the ribbon across the thermal print head during printing.
For D2T2 printing, the dyes should have specific characteristics: a high melting point to prevent plasticisation of the dye-sheet polymer binder, high optical strength for good colour intensity, good affinity and solubility for the binder polymers, and stability to light to prevent fading. The receiver paper or plastic substrate is made of special polymer coatings that receive the dyes during thermal transfer.
One limitation of the D2T2 process is that polymers suitable for laser engraving are often not receptive to dye diffusion, making it challenging to achieve a combination of engraved and full-colour images. Wax thermal transfer, a low-tech alternative, does not offer the same continuous tone images or security as D2T2 printing.
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Laser printing
Laser marking on plastic is a process that uses laser radiation to create markings on plastic surfaces. This method offers high precision, visibility, and clarity, making it ideal for long-term use. Laser marking is a popular choice for applications requiring traceability marks, barcodes, or other types of identification.
There are several types of laser marking techniques, including laser etching and engraving, which can produce dark or white markings, as well as transparent designs. Laser marking machines are becoming increasingly advanced, incorporating data storage and additional software capabilities. These innovations allow for smaller marking shapes and sizes due to improved beam precision.
Laser marking on plastic can involve simply peeling off the paint or printing on the target surface to expose the base material and create contrast. This technique is commonly used in applications such as automobile instrument panel switches, where it offers a simple and convenient alternative to traditional printing and stamping methods.
The laser marking process can also be used to permanently mark plastic parts. This is achieved by using lasers to etch or change the surface colour of the plastic, creating excellent contrast and readability for codes, text, icons, and logos. Hard-pigmented and soft-pigmented inks are used to print high-contrast, high-quality marks on dark and challenging plastic substrates.
Videojet offers a range of laser marking systems, including CO2 lasers, fibre lasers, and UV lasers. These lasers can be selected based on the specific material properties, production line speed, and laser wavelength required for the application. Videojet laser systems provide seamless integration, high-speed marking, and high-quality codes, text, and logos on plastic surfaces.
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Sealing the print
Sealing a print on plastic is an essential step to protect it from scratches, abrasion, and airborne pollutants. Here are some detailed instructions on how to seal prints on plastic:
Sealant Testing:
Before applying any sealant to your print, it is recommended to test it on a similar paper scrap. This allows you to observe how the sealant interacts with the paper and ensures that it does not smudge or smear the print.
Paper Choice:
Using a bright white paper with a brightness of 96 US or above is suggested, as it allows the colors to appear brighter and crisper. Additionally, using a color LaserJet printer instead of an inkjet printer can prevent smearing when applying glue.
Sealant Options:
There are various sealant options available, each with its advantages:
- Laminating Film: This method involves encasing the print in a thin layer of plastic, creating a waterproof barrier. It protects the print from moisture and extends its life. Ensure that the edges are properly sealed to prevent water seepage.
- Protective Sprays: These sprays are ideal for smaller prints and provide protection against abrasion, fingerprints, UV light, and airborne pollutants. They form a transparent film that does not alter the paper's structure. However, ensure proper ventilation and safety gear when applying sprays containing solvents.
- UV-Resistant Acrylic Coating Spray: This spray not only seals and protects your artwork but also adds a glossy, crystal-clear finish that enhances the overall look. It dries quickly and is long-lasting, preventing any yellowing effect over time.
- Resin Gloss Sealer Spray: This type of spray sealant is recommended for resin projects. It adds a glossy finish to your prints and can be applied in light coats.
- Clear-Drying White Glue: A simple and effective way to seal your prints is by using a clear-drying white glue. It creates a protective layer over your print.
Additional Tips:
- When using a laminating film, ensure that the adhesive is on the plastic and not the flap to prevent the print from sticking and getting damaged when opened.
- If using aqueous dye inks, encapsulate the print between two sheets of laminating film that are slightly larger, creating a sealed edge to prevent moisture seepage.
- Avoid storing inkjet prints in vinyl plastic sleeves. Smooth polyester sheeting is recommended for safe contact with the print surface.
By following these steps and choosing the appropriate sealant, you can effectively seal your prints on plastic, ensuring their longevity and protection from external factors.
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Frequently asked questions
There are several ways to print on plastic. You can use a pad printer, which requires a printing plate, the right ink, and a machine. Alternatively, you can use screen printing for flat surfaces or laser etching for small-scale projects. For straight-walled plastic containers, dry offset printing can be used.
One way to transfer an image onto plastic is to use a toner transfer method. You can also use printable water slide decals, which allow you to cleanly bond the colour print to the plastic.
Hydro dipping, or immersion printing, is a technique where film is printed on using any inkjet printer and then transferred to the plastic. This method is suitable for designs with single tones or a stack of up to 3-4 colours.
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