Ethan Clarke
Printing on hard plastic is a versatile and durable way to brand products or create custom packaging. There are several methods to print on hard plastic, including digital printing, laser printing, pad printing, and UV inkjet printing. Each method has its advantages and considerations, such as the need for pre-treatment and the durability of the print. The chosen printing method will depend on the specific requirements of the project, such as the desired quality, cost, and intended use of the printed material.
| Characteristics | Values |
|---|---|
| Printing methods | Pad printing, UV inkjet printing, laser printing, dry offset printing, screen printing, digital printing |
| Printing technology | Inkjet technology, laser technology |
| Printing resolution | High |
| Printing adhesion | High |
| Printing durability | High |
| Printing cost | Low to high |
| Printing speed | High |
| Printing compatibility | Depends on the thickness and type of plastic |
| Ink type | UV inkjet ink, solvent-based ink, ink specifically formulated for plastic |
| Ink characteristics | Resistant to fading and smudging, vibrant colours |
| Ink adhesion | Depends on the cleanliness and dryness of the plastic surface |
| Post-printing treatment | UV protective coating, moisture-resistant overcoat |
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What You'll Learn
Choosing the right machine
Printing on plastic requires a good understanding of the printing technologies available and the unique characteristics of plastic materials. The type of printer you use will depend on the specific needs of your project, including the scale of your operations, the type of plastic you are printing on, and the desired print quality.
There are several types of printers that can be used for printing on plastic products, each offering unique benefits. Here are some options to consider:
- Inkjet printers: These printers are versatile and capable of producing high-detail, full-colour images on plastics. They are generally more affordable than laser printers but may not always produce the same high-quality print. Inkjet printers work by spraying tiny ink droplets onto the surface, making them suitable for various resolutions and colour complexities. Handheld inkjet printers are a more flexible variant, perfect for on-the-go printing requirements or printing on large or awkwardly shaped plastics.
- Laser printers: Laser printers use a high-powered laser to etch the design onto the plastic surface. They are suitable for high-quality, precise, and detailed prints. Laser printers are typically very fast and can print at high resolutions, but they can be quite expensive to purchase and maintain. A standard office laser printer can print on plastic to some extent.
- Thermal printers: Thermal transfer printers use heat to transfer ink onto the plastic surface and are suitable for small-scale production runs due to their good print quality. Handheld thermal inkjet printers are portable and can produce high-resolution prints. They are ideal for detailed, small-scale printing on plastic substrates on the go, including packaging and labelling.
- UV printers: UV printers use ultraviolet light to cure the ink, making them suitable for a wide range of plastics, including challenging surfaces like acrylic and polycarbonate. UV prints are durable, high-quality, and resistant to fading. UV printing can also be done using UV inkjet printers, which incorporate post-curing.
- Digital printers: Digital printers, either inkjet or toner-based, can handle almost any type of plastic and are particularly useful for short runs and on-demand printing. They are ideal for detailed, custom designs and offer quick turnaround times and lower costs.
- Flexographic printers: Flexographic printers use flexible rubber plates to transfer ink onto the plastic and are suitable for medium-size or large-scale production runs. They provide a good balance of speed and quality and are commonly used for continuous patterns on materials like LDPE and HDPE.
- Pad printers: Pad printing is a popular process for printing 1- to 6-colour graphics. It involves mixing a solvent-based pad printing ink with solvent, hardener, and other additives, which are then placed on a printing pad and stamped onto the product. Pad printers are ideal for three-dimensional objects and printing on irregular surfaces.
- Screen printers: Screen printing involves transferring ink through a stencil onto a plastic substrate. It is ideal for high-volume, durable prints and is commonly used for items like plastic containers and promotional products.
When choosing a machine, it is important to consider factors such as speed, precision, and durability, as well as the specific printing process you will be using, such as thermoforming, injection moulding, or extrusion. Additionally, ensure that the printer and ink are compatible with the specific type of plastic you are using to achieve optimal results.
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Selecting the right type of plastic
For instance, if you are creating temporary signage for a clearance sale, a low-cost plastic like HIPS (High Impact Polystyrene) might be a suitable option. HIPS is commonly used in retail displays and indoor banners and offers a print-friendly surface. However, it is extremely brittle and does not die-cut well, so it may not be suitable for applications that require durability or precision.
On the other hand, if you need a plastic that is strong and durable, PVC (Polyvinyl Chloride) or polycarbonate might be better choices. PVC is widely used, tough, and easy to die-cut, making it versatile for applications like cards, pipes, and records. However, it has a reputation for being environmentally unfriendly due to the creation of volatile organic byproducts during production and its lack of recyclability. Polycarbonate, while more expensive, is easier to work with and produces better results. It is also more heat-resistant, making it ideal for projects involving high temperatures.
If flexibility is a key requirement, PETG (Polyethylene Terephthalate Glycol-modified) is a good option. It is similar in price and quality to polycarbonate but offers more flexibility, making it suitable for applications where pliability is important.
For those seeking an environmentally friendly option, polylactic acid (PLA) is a popular choice. It is made from renewable materials and is known for its low cost, ease of manufacture, versatility, and water resistance.
Ultimately, the right type of plastic depends on the specific requirements of your project, including factors such as durability, flexibility, environmental impact, cost, and compatibility with your printing technology.
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Preparing the plastic surface
Firstly, it is essential to assess the type of plastic and its characteristics. Consider the durability and thickness of the plastic, ensuring it meets the requirements of the intended use. Different types of plastics, such as PVC, polycarbonate, and PETG, have unique benefits and drawbacks, so choosing the right one is important. For instance, polycarbonate is more heat-resistant, making it suitable for high-temperature projects.
Before printing, the plastic surface must be thoroughly cleaned to remove any dirt, dust, or debris that might compromise print quality. It is imperative to ensure that the surface is entirely free of oils or residues that could hinder ink adhesion. A simple wipe with a suitable cleaning agent can be used for this step.
The next step is pre-treatment, which is crucial for preparing the plastic surface to accept the ink. The specific pre-treatment method depends on the type of plastic and the intended use of the printed product. For example, some very hard plastics, such as PP, Nylon, and HDPE, require pre-treatment, which can be in the form of chemical pre-treatment, flame treatment, or corona treatment. Chemical pre-treatment typically involves wiping the product with a chemical solution to prepare its surface for printing.
After pre-treatment, a primer is often applied to further enhance ink adhesion and print quality. Primer wipes are commonly used, especially for promotional products or flat items that won't be exposed to harsh conditions like a dishwasher. However, for products that will be washed frequently, additional pre-treatment steps like flame or corona treatment can be considered.
For UV printing, an inkjet primer is usually required, and the specific type of primer will depend on the intended use case and the type of plastic being printed on.
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Using the correct ink
Printing on hard plastic requires the right type of ink to ensure durability, colour vibrancy, and resistance to fading. The ink you choose will depend on the type of plastic you are printing on and the printing method you are using.
For example, if you are using a UV inkjet printing process, you will need a UV inkjet ink that can be cured using the UV/LED light that comes standard with the machine. This type of ink is designed to be jetted onto the product in tiny droplets, forming the image created on the computer. An inkjet primer is usually needed for most plastics, and additional pre-treatment steps may be required for items that will be washed frequently, such as drinkware.
On the other hand, if you are using a pad printing process, you will need to use a different type of ink specifically designed for pad printing. Most solvent-sensitive products will not need pre-treatment, as the solvent in the ink will alter the surface tension of the product, allowing the ink to adhere. However, products that are not solvent-sensitive, such as very hard plastics, will need to be pre-treated chemically, with flame, or with corona.
It is important to consider the durability of the plastic and the thickness of the material, as these factors will affect both the printing process and the end use of the product. The printability of the plastic, including its compatibility with your chosen printing technology, should also be evaluated. Additionally, the surface of the plastic should be cleaned thoroughly to remove any dirt, dust, or debris that might affect print quality, and it should be ensured that the plastic is dry and free of oils or residues that could interfere with ink adhesion.
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Applying protective coatings
Printing on plastic is different from printing on paper. Inks, varnishes, and coatings will lie on the surface of these non-absorbent substrates and will not be absorbed. The surface of plastic materials also lacks bonding sites for printed/coated products and foil stamping adherence. Therefore, it is important to apply a protective coating to ensure the print's durability.
Before applying a protective coating, it is important to clean the surface thoroughly to remove any dirt, dust, or debris that might affect print and coating quality. Ensure the plastic is dry and free of oils or residues that could interfere with ink adhesion. Rub and friction points should be covered with protective smooth Teflon tape.
If the printed item will be exposed to sunlight, apply a UV protective coating to prevent fading and deterioration. For prints that will be handled often, such as notecards, album pages, or portfolio prints, use protective sprays to protect against abrasion, fingerprints, ultraviolet (UV) light, and airborne pollutants. These sprays form a fine, transparent film that does not affect the structure of the paper. Some protective sprays available for protecting aqueous inks include Moab Desert Varnish, PremierArt PrintShield, Marabu ClearJet Original Type A, and Hahnemuhle Protective Spray.
If the printed item will be exposed to humid or wet environments, consider using a moisture-resistant overcoat. For transparent plastics, such as polycarbonate, acrylic, and molded parts with a high gloss finish, consider using NANOMYTE® coatings, which provide scratch resistance and superior water repellency.
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Frequently asked questions
The best methods for printing on hard plastic are pad printing, UV inkjet printing, and laser printing.
You will need a printer designed for plastic substrates, ink formulated for plastic, and the plastic material you will be printing on. You may also need to apply a protective coating to the printed items if they will be exposed to sunlight or moisture.
The surface of the hard plastic should be cleaned thoroughly to remove any dirt, dust, or debris that might affect print quality. It should also be dry and free of any oils or residues that could interfere with ink adhesion. Depending on the type of plastic, you may need to apply a primer or chemical pre-treatment to the surface before printing.
