Alexei Volkov
Printing on plastic cards or containers is a complex process that requires careful preparation and the right equipment. It involves using specific printers and techniques, such as Continuous Inkjet (CIJ) Printers, Laser Systems, or UV Printers, each with its advantages and limitations. Before printing, it is crucial to consider factors such as ink adhesion, the type of plastic material, and regulations for printing essential product information. Additionally, the choice of equipment depends on the desired quality, efficiency, and specific needs of the project. CAD (Computer-Aided Design) files play a vital role in 3D printing, offering a range of file types like STEP, STL, IGES, and more. These files can be exported and configured for 3D printing, ensuring accuracy and precision in the final product.
| Characteristics | Values |
|---|---|
| Printing on plastic containers | Various methods and technologies are available, including Continuous Inkjet (CIJ) Printers, Laser Systems, and UV Printers. |
| Choosing the right equipment | Consider the type of plastic material used, such as polystyrene, polypropylene, polyester, or polyvinyl chloride (PVC), as it will impact the printing process and final results. |
| Ink adhesion | Some plastics may require pre-treatment to ensure proper ink adhesion. |
| Durability | Laser systems and UV printers offer durable printing options. |
| Scratch resistance | UV printers provide scratch-resistant prints. |
| Image quality | UV printers are suitable for high-quality images, graphics, or text due to their excellent color reproduction and print clarity. |
| Cost | The cost of printing on plastic depends on factors such as ink/ribbon choice, color, and quantity. |
| File format | 3D CAD software is used to create a mathematical model of the design, containing all the dimensional data. |
| 2D CAD drawing | A 2D CAD drawing is a snapshot of the part from one perspective, requiring the designer to specify important details about the part's appearance, texture, and function. |
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What You'll Learn
3D printing on plastic with CAD files
3D printing on plastic typically involves using CAD files, which are computer-aided design files. There are various types of CAD files, including Native CAD files and Neutral CAD files. Native CAD files are copyrighted intellectual property of the system/CAD program for which they are used. On the other hand, Neutral CAD files are open-format and not copyrighted, making them ideal for sharing across multiple CAD platforms. However, they may result in a slight loss of fine details when converted to a neutral file type. Examples of Neutral CAD files include .stl, .amf, .obj, and .stp.
When preparing CAD files for 3D printing, it's essential to ensure the file format is compatible with the 3D printer's requirements. The two main types of structured files acceptable for 3D printing are mesh and parametric. The most common parametric file type used in 3D printing is the STL (Stereolithography or Standard Tessellation Language) file. STL files are widely recognised as the industry standard for additive manufacturing. They describe the surface of an object by dividing it into triangles and providing the location and orientation of each triangle's points. However, they have limitations, such as dimensional ambiguity and issues with watertightness.
To address the shortcomings of STL files, newer and optimised file formats, such as STEP (Standard for the Exchange of Product model data), are being favoured. STEP files are considered the best format for transferring CAD data and are less prone to the issues associated with STL files. When using STL files, it's crucial to ensure they have a single, solid body. Overlapping bodies can lead to build defects and crashes in the 3D printing machine. Therefore, any unnecessary components should be removed from the file rather than simply hidden, as this can cause errors during the exporting process.
Additionally, when working with existing parts without CAD drawings, it is possible to generate a 3D model from 2D photographs. Software and equipment are available to facilitate this process, and services even offer 3D printing of one's body. However, for small parts that require precise measurements, 3D scanning or photogrammetry may not be suitable, as they often result in models that need cleanup and cannot be printed directly. In such cases, modelling from scratch or using an online 3D editor like TinkerCad might be more effective.
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Choosing the right equipment for printing on plastic
Printing on plastic requires the right equipment to achieve quality results. The type of printer and ink used are crucial factors in the printing process. Here are some guidelines to help you choose the right equipment for printing on plastic:
Printer Types
Digital Inkjet Printing: This method uses inkjet technology to produce high-quality images directly on plastic surfaces. It offers quick turnaround times, lower costs, and customisation options for small batches. This process is ideal for personalised items like gift cards, ID cards, and loyalty cards.
Screen Printing: This method transfers ink through a stencil onto plastic substrates. It is suitable for applications that require durable and long-lasting prints. Screen printing is cost-efficient for large quantities and provides a cost-effective solution for printing on plastic.
Laser Printing: Laser printing uses a focused laser beam to heat and melt the plastic surface, creating precise and detailed designs or images. It is suitable for intricate designs and industrial-grade applications. Laser printing is environmentally friendly, producing minimal waste.
Handheld Thermal Inkjet Printers: These portable printers use heat to expel ink droplets onto the plastic surface, offering high-resolution prints. They are ideal for small-scale printing on plastic substrates and are compact, easy to use, and low maintenance.
UV Printing: UV printing, also known as UV inkjet printing, uses UV/LED light to cure the ink directly onto the plastic substrate. This process creates durable prints that resist fading and smudging.
Pad Printing: Pad printing involves mixing solvent-based pad printing ink with a solvent, hardener, and other additives. The ink is added to a cup and placed on a pad printing machine, which acts as a stamp to transfer the artwork to the product. This method is popular for printing 1- to 6-colour graphics.
Ink Considerations
When printing on plastic, it is essential to choose inks specifically formulated for plastic adhesion. These inks ensure durability, colour vibrancy, and resistance to fading. Additionally, consider applying a UV protective coating if the printed items will be exposed to sunlight, and a moisture-resistant overcoat for protection in humid or wet environments.
Plastic Type
The choice of plastic material is also important. Common options include PVC (polyvinyl chloride), known for its toughness and durability; polycarbonate, which is heat-resistant and produces high-quality results; and PETG, which is flexible and ideal for applications requiring flexibility.
Other Factors
When printing on plastic, it is crucial to consider the durability, thickness, and printability of the plastic material. Ensure the plastic surface is clean and free from oils or residues that may interfere with ink adhesion. Additionally, factor in the cost of ribbons or ink, as colour options tend to be more expensive.
By selecting the right printer, ink, and plastic type, you can achieve high-quality and durable results when printing on plastic.
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Using Continuous Inkjet (CIJ) Printers for plastic
Continuous Inkjet (CIJ) printers are a versatile, non-contact printing method that can print on almost any substrate, including plastic. CIJ printers are ideal for printing on flat and curved surfaces, and they can be easily integrated into high-speed production lines. With over 50 years of development experience, CIJ printers from companies like Videojet and Markem-Imaje offer a range of features and benefits that make them a popular choice for manufacturers.
One of the key advantages of CIJ printers is their flexibility. They are capable of coding all packaging types, sizes, and line speeds while ensuring traceability throughout the supply chain. This makes them a cost-effective solution for manufacturers, as they can use a single printer for multiple applications. CIJ printers also offer a wide range of ink options, including dye-based and pigmented inks, to meet the specific needs of different industries and applications.
Another benefit of CIJ printers is their ease of use and reliability. They are designed to be user-friendly, with features like the Smart Cartridge™ fluid delivery system from Videojet, which helps eliminate spills and ensure the correct fluid usage. CIJ printers also have long run times between preventive maintenance, reducing downtime and improving efficiency. Additionally, features like auto-cleaning printheads and on-board Code Assurance help prevent coding mistakes and ensure fast start-ups.
CIJ printers are also known for their speed and performance. The Jet Speed Control feature from Markem-Imaje automatically adjusts ink and printer variables to ensure perfect drop placement, quality, and code consistency. The Intelli’Design principle allows for easy adaptation to marketplace needs, and the customizable 24-pin interface enables seamless integration into Industry 4.0. CIJ printers can also handle a wide range of industrial protocols, further enhancing their compatibility and performance.
Overall, Continuous Inkjet (CIJ) printers offer a flexible, reliable, and high-performance solution for printing on plastic and other substrates. With their ability to handle high-speed production, ease of use, and wide range of ink options, CIJ printers are a popular choice for manufacturers looking for a cost-effective and efficient printing solution.
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Laser systems for printing on plastic
Laser marking systems are a popular choice for printing on plastic. They offer a range of benefits, including durability, precision, and cost-effectiveness. Laser marking machines can create permanent, high-quality marks on plastic surfaces with minimal distortion and resistance to chemicals, abrasion, and extreme temperatures.
There are several types of laser marking machines available, such as fiber lasers and CO2 lasers, which can be used to engrave various plastics, including acrylic, polyethylene, polypropylene, and polyester. These lasers can mark simple codes or complex graphics, barcodes, serial numbers, and logos. Laser marking is also versatile, suitable for industries such as manufacturing, packaging, aerospace, and consumer goods.
One advantage of laser marking systems is their adaptability to different plastic types and colours. They can provide optimal contrast and legibility, ensuring that the markings are clear and sharp. Additionally, laser marking machines reduce ongoing costs by minimising the use of consumables and eliminating the need for inks or chemicals.
Laser marking machines also offer time-saving benefits. They can process large work areas and engrave multiple pieces simultaneously, making them efficient and productive. Furthermore, laser marking systems are user-friendly, easy to operate, and can be integrated into existing production lines, making them a reliable and low-maintenance solution.
Overall, laser marking systems provide an effective and efficient way to print on plastic, offering high-quality, permanent markings with minimal distortion and resistance to various elements. These systems are adaptable, versatile, and cost-effective, making them a popular choice for industries requiring plastic printing solutions.
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UV printers for high-quality images on plastic
UV printers are an excellent option for printing high-quality images on plastic. This technology uses ultraviolet light to cure ink on a wide range of surfaces, including plastic, and offers several advantages over traditional printing methods.
UV printing can produce high-quality images with vivid colours and sharp details. The prints are resistant to fading, scratching, water, and chemicals. This printing method also saves time, energy, and resources by eliminating the need for drying or coating processes associated with traditional printing.
When it comes to printing on plastic, UV printers offer unparalleled versatility and accuracy. They can accommodate various plastic shapes and sizes, making them ideal for diverse applications such as cards, keychains, phone cases, and larger products like tents. Additionally, UV printers can handle large volumes efficiently, significantly reducing production time.
Several UV printer manufacturers, such as Mimaki, Roland, Direct Color Systems, and HP, offer machines capable of producing high-resolution prints on plastic. When choosing a printer, it is essential to consider your specific requirements, such as the desired image size and the number of colour channels needed. It is recommended to obtain samples from local dealers by supplying them with the media and images you want to be printed, allowing you to evaluate the quality before making a purchase.
Overall, UV printers provide a flexible, efficient, and high-quality solution for printing images on plastic, making them a valuable tool for businesses seeking to customise and brand their products.
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Frequently asked questions
There are various methods for printing on plastic, including Continuous Inkjet (CIJ) Printers, Laser Systems, and UV Printers. The choice of equipment depends on the specific needs and requirements of the project. It is also important to consider factors such as ink adhesion and the type of plastic material used.
Some common plastic materials used for printing include polystyrene, polypropylene, polyester, and polyvinyl chloride (PVC). Each material has unique characteristics that can affect the printing process and final results.
It is important to properly prepare the plastic surface before printing. This may include pre-treating the plastic to ensure proper ink adhesion. Additionally, the desired print quality and durability should be considered, as well as any relevant regulations and codes, especially when printing essential product information such as expiration dates and barcodes.
