Omar Khalid
Printing on plastic boxes is a versatile and durable way to brand products and create visually appealing designs. There are several methods to print on plastic, including digital inkjet printing, flexography, pad printing, and laser printing. Each method has its advantages and considerations, such as the type of plastic used, ink adhesion, and desired print quality. Before printing, it is essential to clean the plastic surface and consider the thickness and printability of the plastic material. Choosing the right equipment, such as a Continuous Inkjet (CIJ) printer or laser system, can ensure efficient and high-quality printing on plastic boxes.
| Characteristics | Values |
|---|---|
| Printing process | Pad printing, rubber pad printing, flexography, digital ink jet printing, screen printing, laser printing, thermal inkjet printing, continuous inkjet printing |
| Printing surface | Flat or curved |
| Ink | Regular, soft-pigmented, UV-cured, moisture-resistant, formulated for plastic |
| Printing machine | Videojet printers, standard office laser printer, pad printer |
| Plastic type | Polyvinyl chloride (PVC), polycarbonate, PETG, polystyrene, polypropylene, polyester |
| Other | Cost, speed, durability, compatibility, print quality, resolution, adhesion, protection from sunlight, humidity, or wetness |
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What You'll Learn
Choosing the right printing machine for plastic
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 use case and the type of plastic you are printing on.
Inkjet Printing
Inkjet printers are versatile and capable of producing high-detail, full-colour images on plastics. They work by spraying tiny ink droplets onto the surface, making them suitable for various resolutions and colour complexities. They are also relatively low cost and can be used for small batches.
Laser Printing
Laser printers are excellent for smooth plastics such as PVC and PET. They offer precision, speed, and high-quality text and image reproduction. Laser printers are often used for intricate designs as they allow for more precision than inkjet printing. However, they are typically more expensive upfront and produce toxic fumes during operation.
Thermal Printing
Thermal printers are commonly used for labels and barcodes on plastic. They transfer images via heat, which works well with plastics like HDPE and LDPE.
UV Printing
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.
Digital Printing
Digital printers can handle almost any type of plastic and are particularly useful for short runs and on-demand printing.
Flexographic Printing
Flexographic printing is used for large-scale printing on plastic films and is suited for continuous patterns on materials like LDPE and HDPE. This method is fast and efficient, with quick drying times, but the initial setup cost can be substantial.
Dye Sublimation Printing
Dye sublimation printers use heat to transfer dye onto plastic. This method creates a gradual blend between colours, making it perfect for photographic images and vibrant designs. Dye sublimation printing is ideal for promotional goods and personalised items due to its ability to print intricate, full-colour designs.
Pad Printing
Pad printing is a popular process for printing on plastic, especially for companies looking to print 1- to 6-colour graphics. The ink is added to an ink cup and placed on the pad printing machine, which acts as a stamp to transfer the artwork onto the product.
Hot Stamping
Hot stamping is a fast, efficient, and affordable method for printing on plastic bags. The design is imprinted onto the surface of the bag in a matter of seconds using a hot stamp machine.
Rotogravure Printing
Rotogravure printing uses an engraved metal cylinder to transfer ink onto the plastic surface. It is ideal for large-scale production due to its precision and high speeds.
When choosing a printing machine for plastic, it is important to consider the specific type of plastic being used, the desired print quality and durability, and the intended use of the printed product.
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Selecting the right type of plastic
When selecting the right type of plastic for your printing project, there are several factors to consider. Firstly, determine the printing process you will be using, as different processes have unique requirements. For example, common plastic printing processes include thermoforming, injection moulding, and extrusion.
The next step is to choose a suitable plastic material that is compatible with your printing technology and meets the specific demands of your project. Assess the durability, thickness, flexibility, and printability of the plastic. Some popular choices include PVC (polyvinyl chloride), polycarbonate, and PETG. PVC is known for its toughness and durability, but it can be challenging to work with and may not yield the highest-quality prints. On the other hand, polycarbonate is easier to work with, produces better results, and is more heat-resistant, making it ideal for projects requiring high temperatures. PETG, similar in price and quality to polycarbonate, offers more flexibility, making it suitable for applications requiring flexibility.
If you are using 3D printing technology, there are several types of plastics to choose from, each with unique advantages. PLA, for instance, is increasingly popular due to its eco-friendliness, reliability, and availability in both soft and hard forms. ABS is another common choice, known for its safety, durability, and flexibility, and it is often used in home-based 3D printers. Additionally, high-performance plastics like PEEK, PEKK, and ULTEM offer exceptional mechanical and thermal resistance while being significantly lighter than metals, making them attractive for aerospace, automotive, and medical applications.
For projects requiring lightweight yet strong parts, composites are ideal. These utilize short or continuous fibres to enhance the stiffness and strength of the plastic without adding weight. Common fibres include carbon fibre, fiberglass, and Kevlar, which can be mixed with thermoplastics like nylon, ABS, or PLA. Furthermore, hybrid materials combine a base, such as PLA, with a powder to create unique colours or surface finishes, including organic structures from materials like bamboo or cork.
The versatility of plastic allows for various printing methods, from digital printing with inkjet technology to traditional methods. Consider the desired shape, size, colour, and texture of your final product when selecting the right type of plastic.
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Preparing the plastic surface
Firstly, identify the type of plastic your box is made of. Common types include polypropylene (PP), polyethylene terephthalate (PET), and nylon. Each type of plastic has unique properties that will influence the preparation and printing process.
Next, determine if your plastic requires pre-treatment. Solvent-sensitive plastics, for example, typically do not need pre-treatment as the solvent in the ink will allow the ink to adhere. However, non-solvent-sensitive plastics like PP, nylon, and HDPE will likely require pre-treatment. A chemical pre-treatment wipe can be used to prepare the surface of these plastics. Alternatively, flame or corona treatments can be applied to enhance the surface's ability to bond with the ink.
Once pre-treatment is complete, ensure the plastic surface is clean and free of any contaminants that may hinder ink adhesion. This step is crucial in ensuring a high-quality print.
If you are using a printing method like hot stamping, you will need to apply a heat-activated adhesive or coating to the plastic surface. This will enable the foil to adhere properly during the transfer process.
Finally, test the printing process on a small area of the plastic surface. This will allow you to fine-tune any parameters, such as ink viscosity or pressure, to ensure optimal results during the actual printing process.
By following these steps, you can effectively prepare the plastic surface of your box for printing, ensuring a durable and high-quality outcome.
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Using the right ink for plastic
Printing on plastic requires the right type of ink to ensure the print is durable and of good quality. There are several printing methods that can be used on plastic, each requiring a different type of ink.
Digital Inkjet Printing
Inkjet printing uses special ink that dries by evaporation, allowing the ink to adhere to plastic. This method is ideal for one-off prints or short production runs. However, inkjet inks are expensive, making them unsuitable for long production runs. Inkjet printing also includes UV inkjet printing, which uses UV light to cure the ink. This method requires an inkjet primer and may require pre-treatment depending on the intended use.
Pad Printing
Pad printing involves mixing solvent-based pad printing ink with a solvent, hardener, and other additives. This method is popular for printing multi-color graphics and is suitable for a range of plastics. Pad printing is a simple and economical process, making it a common choice for printing on plastic.
Screen Printing
Screen printing is a traditional method that uses blocking stencils on a fine silk mesh to transfer the design onto the plastic. This method is suitable for printing on plastic film, which can then be transferred to shaped packaging. Screen printing is recommended when using a regular inkjet printer as the ink dries quickly and is scratch-proof and waterproof.
Thermal Inkjet (TIJ) Printing
TIJ printing is an advanced ink-based technology that provides high-quality, precise printing on plastic. It is ideal for applications requiring high-resolution text, barcodes, or logos. TIJ printing is versatile and can be used on a wide range of plastic surfaces, including bottles, containers, and jars.
Laser Printing
Laser printing uses a laser to produce high-quality, permanent codes or designs on plastic. This method typically results in a color change or engraving effect. Laser printing is suitable for a range of plastics, including high-density Polyethylene (HDPE) and Polyvinyl Chloride (PVC).
When choosing the right ink for printing on plastic, it is important to consider the type of plastic, the desired print quality, and the intended use of the printed product.
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Applying a protective coating
Printing on plastic can be a tricky process due to the material's unique properties. Unlike paper, plastic substrates do not absorb ink, varnish, or coatings. Instead, these lie on the surface of the plastic. This can make it challenging to achieve the desired adhesion and durability for your print. To enhance the longevity of your print, applying a protective coating is essential.
There are various protective coatings available, each with its own advantages and considerations:
Liquid Coatings
Liquid coatings dry on the surface of the print, creating a thin barrier film that shields the ink and the underlying material. Different formulations of liquid coatings are available to suit specific applications, such as inkjet canvas, indoor wall coverings, or outdoor signs. For instance, clear coats for outdoor signs must be able to withstand exposure to rain without running or dissolving. When printing with aqueous dye inks, a solvent-based clear coat is necessary, such as the ClearJet FineArt or ClearJet A2000 Solvent-Based coating. Alternatively, water-based coatings, like ClearJet Classic or ClearJet Select, can be used with pigment-ink printers and vinyls or water-resistant canvas.
Protective Sprays
Protective sprays are an easy and efficient way to safeguard prints on fine art papers from various elements, including abrasion, fingerprints, UV light, and airborne pollutants. These sprays are commonly used for items that require handling, such as notecards or album pages. The spray forms an invisible film that preserves the print's original colour without altering its structure. However, it's important to apply these sprays in a well-ventilated area due to the presence of solvents. Protective sprays like Moab Desert Varnish, PremierArt PrintShield, and Marabu ClearJet Original Type A are commonly used.
Archival Storage
Another aspect of protection involves the storage of your printed plastic items. To prevent damage from air, light, and acidic environments, it is recommended to use archival-grade storage options that meet specific ISO standards. These enclosures should be acid-free, lignin-free, and free from certain adhesives and plastics. Additionally, they should contain an alkaline reserve to protect the paper from environmental acids.
Gloss Coatings
For a glossy finish, you can use a product like XTC-3D Brush-On Coating, which provides a hard, shiny surface. Alternatively, Pledge Revive Floor Coat can add sheen without creating a hard plastic-like coating.
When choosing a protective coating, it is essential to consider the specific type of plastic, the desired level of protection, and the intended use of the printed item. Each coating has unique characteristics, and some may be better suited for certain plastics or applications than others. By selecting the right coating and following the application instructions carefully, you can effectively enhance the durability and longevity of your print on plastic boxes.
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Frequently asked questions
There are several methods to print on plastic boxes, including Continuous Inkjet (CIJ) printing, laser marking, rubber pad printing, digital inkjet printing, screen printing, flexography printing, and thermal inkjet (TIJ) printing.
When choosing a printing method for plastic boxes, it is important to consider the type of plastic used, the thickness of the plastic, the compatibility of the plastic with the printing technology, and the intended use of the box.
Before printing on a plastic surface, it is essential to clean the surface thoroughly to remove any dirt, dust, or debris that may affect print quality. Ensure the surface is dry and free of oils or residues that could interfere with ink adhesion.
When printing on plastic boxes, it is recommended to use high-quality printers and inks specifically designed for plastic substrates. Applying a UV protective coating can help prevent fading and deterioration if the boxes are exposed to sunlight. Consider using a moisture-resistant overcoat for protection in humid or wet environments.
