Maya Ellison
Printing on plastic is a great way to personalise items, but it can be tricky. There are many different types of plastic, and each has its own unique composition and characteristics. Printing on plastic is not the same as printing on paper, and there are several different methods to print on plastic. These include digital ink jet printing, screen printing, flexo printing, pad printing, UV litho printing, heat transfer printing, and hydrographic printing.
| Characteristics | Values |
|---|---|
| Printing Methods | Digital Ink Jet printing, Screen printing, Flexo printing, Pad printing, Laser printing, UV Litho printing, Heat transfer printing, Hydrographic printing, In-mold design (IMD) or in-mold labeling (IML), Digital UV printing, Sublimation |
| Printing on Plastic Sheets | Use an inkjet printer, not a laser printer, load a single plastic sheet rough side down, allow prints to dry before handling |
| Printing on Plastic Bags | Use screen printing, place cardboard pieces inside each bag to prevent ink from soaking through |
| Printing on Phone Cases | Use silk or screen printing, heat transfer printing, hydrographic printing, in-mold design (IMD) or in-mold labeling (IML), digital UV printing |
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What You'll Learn
Digital inkjet printing
The process of digital inkjet printing on plastic cases involves using one or more printheads and may include additional steps for surface preparation or pretreatment, part feeding, static mitigation, and post-coating. The selection of the appropriate ink is critical to ensure the ink has the correct viscosity to form droplets and adhere to the plastic surface. Solvent-based inks, for example, can provide waterproof and scratch-proof results on plastic, but they are typically used with large-format inkjets rather than regular inkjet printers.
When printing on plastic cases, it is important to consider the expected print area, production rates, and part size. Single-pass inkjet systems tend to be faster due to their throughput being determined by linear speed. However, full-colour printing with a scanning system may be slower, similar to a desktop printer. Additionally, the type of inkjet printer and ink used can impact the results. Flat-bed inkjet printers, for instance, can print full colour on iPhone covers with scratch- and water-resistant finishes, but they are generally more expensive.
For at-home printing on plastic sheets, an inkjet printer is required as laser printers can burn and destroy the plastic. The plastic sheet should be loaded rough side down, as the rough side captures the ink and prevents smearing. It is important to ensure that the printer has enough ink and that the prints are allowed to dry before handling to avoid smudging. While digital inkjet printing offers flexibility and high-quality results, it is important to consider the limitations, such as the cost of inks and the potential for smudging or smearing with certain ink and printer combinations.
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Flexo printing
Flexography, often abbreviated to flexo, is a form of printing that utilizes a flexible relief plate. It is a modern version of letterpress, which can be used for printing on almost any type of substrate, including plastic, metallic films, cellophane, and paper. Flexo printing is a fast and cost-effective process best suited to printing on thinner, flexible substrates such as plastic bags, vinyl labels on a roll, and food packaging.
The flexo printing process involves the use of anilox rollers to deposit ink onto the surface of an image carrier wrapped around a rotating cylinder. The plastic substrate is on a backup roll or CI drum, and the image carrier transfers the ink evenly onto the substrate. The surface tension of the ink must be lower than that of the image carrier to ensure proper transfer. This can be adjusted by adding alcohol or other treatments to the ink.
To avoid printing defects, it is important to select the appropriate plastic substrate for your packaging. Most plastic substrates can be treated to increase their surface energy, allowing the ink to stick properly. This results in smoother coverage, fewer pinholes, and overall fewer defects. For large-scale industrial printing, elastomer blend sleeves can be used to improve efficiency and maximize profits.
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Pad printing
The process of pad printing can be further categorized into different types of machines, such as Rotary Pad Print Machines and Cup Slide Pad Print Machines. These machines can be adapted to the customer's needs, whether they require single-color or multicolor printing.
Overall, pad printing is a highly versatile and effective method for printing on plastic cases and a wide range of other surfaces. It offers precise placement of ink, fine details, and high-resolution graphics, making it a popular choice for various applications.
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Silk or screen printing
The process of silk or screen printing involves creating a mesh screen with a stencil of the desired design. The screen is then placed over the plastic product, and ink is poured on top. A squeegee is used to spread the ink across the screen, forcing it through the open spaces in the mesh and onto the plastic surface beneath. This technique can produce intricate designs and minute details, with vivid and enduring colours.
To ensure accurate alignment of colours, registration marks can be used. Each colour layer is applied in sequence, from the lightest to the darkest shade, allowing each layer to dry properly before the next is applied. This prevents smudging and facilitates adequate bonding between each coat of colour.
Overall, silk or screen printing is a versatile and durable method of printing on plastic, offering creativity and practicality for both veterans and newcomers to the technique.
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Heat transfer printing
The process of heat transfer printing typically involves printing the desired image onto a heat transfer paper using specialised inks designed for printing on plastic. This paper is then placed onto the surface of the plastic case and subjected to heat and pressure using a heat press machine. The heat and pressure cause the ink to transfer from the paper onto the plastic surface, creating a long-lasting print.
One advantage of heat transfer printing is its ability to transfer multicolour images in a single pass, making it more efficient than some other printing methods. It is also a cost-effective alternative to other decorating methods, especially for larger orders, as it eliminates the need for multiple screens and drying time between colours.
Overall, heat transfer printing is a versatile and durable method for printing on plastic cases, offering high-quality and vibrant results on a wide range of materials.
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Frequently asked questions
There are several ways to print on a plastic case, including digital ink jet printing, screen printing, flexo printing, pad printing, and UV printing.
It depends on the number of cases you want to print on and the desired quality of the print. Screen printing is better for high-volume orders, while digital ink jet printing is more suitable for one-off prints or short production runs. UV printing allows for high-gloss levels and vibrant colors, resulting in a sharper and crisper image.
Make sure you have an inkjet printer as laser printers can burn the plastic. Take out all the regular paper from your printer and load a single plastic sheet, rough side down, into the printer tray. Print your desired text or image and allow it to dry before handling.
