Chloe Zhang
Printing on plastic is a common practice in modern manufacturing and packaging, used for everything from promotional items to product labels. However, it can be challenging due to the wide variety of plastics and their unique characteristics. To achieve the best results, it is essential to understand the type of plastic being used and select the most suitable printing method. Some of the most common printing methods for plastic include pad printing, UV printing, digital inkjet printing, and screen printing. Each method has its own advantages and considerations, such as cost, image quality, and compatibility with different types of plastic.
| Characteristics | Values |
|---|---|
| Printing Techniques | Pad printing, UV printing, inkjet printing, digital inkjet printing, screen printing, laser printing |
| Printing Equipment | Inkjet printers, laser systems, UV printers |
| Plastic Types | Polystyrene, polypropylene, polyester, polyvinyl chloride (PVC), polycarbonate, PETG, ABC, PLA, TPU, Nylon |
| Pre-Printing Steps | Surface cleaning, pre-treatment, adhesion testing |
| Post-Printing Steps | Curing by heat or air, post-cure |
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What You'll Learn
Pad printing
The process involves transferring a 2-dimensional image onto a 3-dimensional object using a silicon pad and a printing plate. The pad printing machine acts as a stamp, picking up the artwork from an etched plate or cliché and placing it onto the product. The ink used in pad printing is specifically chosen for the substrate being printed on and is mixed with a solvent, hardener, and other additives. This mixture assists in the transfer and drying of the ink.
When preparing to print on plastic, it is essential to consider factors such as ink adhesion, pre-treatment, and the type of plastic material used, as these will impact the quality and durability of the final result.
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Inkjet printing
There are a few things to consider when using inkjet printing on plastic. Firstly, it is important to choose the right combination of hardware and ink to create legible and long-lasting prints. Different types of plastics have different surface energies and properties, so it is crucial to select an ink formula that is compatible with the specific type of plastic being used. For example, the ink formula used to mark PVC pipes would differ from the formula used for flexible LDPE wrap.
Another consideration is the use of pre-treatment and primers. Some plastics may require pre-treatment or a primer to ensure proper ink adhesion. However, there are also specialty UV inks available that can adhere to certain plastics without pre-treatment, such as the T2 UV ink for Tritan Plastic.
When it comes to the printing process itself, inkjet printing involves jetting tiny droplets of ink onto the product to form the desired image. This can be done using a standard inkjet printer or a flat-bed inkjet printer, depending on the size and type of plastic being printed on. Flat-bed inkjet printers, for example, are often used for printing on iPhone covers, while standard inkjet printers can be used for thin plastic sheets.
It is worth noting that solvent-based inks designed for large format inkjets can provide waterproof and scratch-proof prints on plastic. However, regular inkjet printers that use water-based inks are not suitable for printing directly onto plastic as the ink will not dry and will smudge. In this case, it is recommended to use screen printing or thermal transfer methods instead.
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UV printing
Printing graphics on plastic requires a thoughtful approach to ensure the desired quality and efficiency. One of the most popular methods for printing on plastic is UV printing, which produces stunning, high-quality, full-colour graphics. UV printing is a direct-to-substrate process that can be used for a variety of weather-resistant signage, branding logos, and marketing products made from acrylic or other plastics.
When using UV printing, an inkjet primer is typically needed for most plastics. The artwork is created and manipulated using design software such as Photoshop or Illustrator, and then sent to the printer. The UV inkjet ink, composed of cyan, magenta, yellow, and black colours, is jetted onto the plastic in tiny droplets to form the desired image. This ink is then cured using UV/LED light, a standard feature of all UV printing machines.
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Screen printing
The screen printing process can be mechanised or done manually. It involves creating a mesh screen with a framed graphic, which is then used as a substrate for the ink. The ink is chosen based on the type of plastic being printed on, with considerations such as brightness, colour, viscosity, and adhesion playing a role in the decision. After printing, a thin layer of varnish is sprayed onto the surface to improve brightness and protect the ink layer.
Before printing, the plastic surface must be thoroughly cleaned to ensure that the designs adhere well. This can be done with a soft cloth and a gentle cleaning solution for curved surfaces, or by wiping in one direction with a suitable solution for flat plastic sheets. It is also important to avoid touching the printing surface with fingers or using sharp objects that could damage the plastic.
To ensure the quality of screen printing on plastic, several acceptance criteria tests can be performed. These include tape tests, where tape is applied and removed from the printed surface at a 45-degree angle, and cloth tests, where a cloth with a gasoline-alcohol mixture is used to rub the surface. The printed pattern should remain intact without showing any gaps or breaks during these tests.
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Laser printing
Laser marking on plastic is a process that uses laser radiation on transparent plastics to create excellent contrasting markings. The laser marking beam is absorbed by the plastic, resulting in darker or lighter markings depending on the material composition. Laser marking machines are now advancing beyond printing or labelling machines, offering data storage and additional software for marking. Laser marking is also capable of creating smaller marking shapes and sizes due to beam precision.
Laser marking on plastic offers several benefits, including clarity, precision, and visibility, making it ideal for long-term results. It eliminates the need for consumables and potential contamination associated with printing and labelling. Laser marking is also a versatile process, capable of cutting, peeling, drilling, and cleaning.
When using laser marking on plastic, it is important to consider the type of plastic material. Common plastic materials include polystyrene, polypropylene, polyester, and polyvinyl chloride (PVC). Each material has unique characteristics that can affect the laser marking process and the final results.
To achieve the best results with laser marking on plastic, the surface should be thoroughly cleaned to remove any dust or residue. This ensures that the laser markings adhere well to the plastic surface. For curved surfaces like plastic bottles, a soft cloth and gentle cleaning solution should be used to prevent scratches. Flat plastic sheets should be wiped in one direction to eliminate streaks.
Laser marking systems, such as those offered by Videojet, can create permanent marks on plastic parts by etching or changing the surface colour. These systems offer high-contrast, permanent coding on plastic, making them ideal for high-speed marking applications. Videojet's laser marking systems also include accessories like lenses and beam-turning units to maximise laser performance and simplify line integration.
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Frequently asked questions
Common methods of printing on plastic include digital inkjet printing, pad printing, screen printing, and UV printing.
Pad printing is a simple process where the image is etched onto a silicone plate, flooded with ink, and wiped clean, leaving ink only in the etched area. Once the ink is tacky, it clings to the printing pad, and the pad is pressed onto the product, leaving the image behind.
Digital inkjet printing uses inkjet technology to print high-quality images onto plastic surfaces. This process uses a digital file containing the image or text to be printed, which is then processed by a printer that uses inkjet nozzles to deposit ink onto the plastic substrate.
Common plastic materials include polystyrene, polypropylene, polyester, and polyvinyl chloride (PVC). Each material has unique characteristics that can affect the printing process and final results, so it's important to understand the type of plastic being used.
