Maya Ellison
Printing on plastic film can be done through various methods, including flexography, inkjet printing, pad printing, screen printing, flat-bed printing, and thermal transfer printing. The chosen method depends on factors such as the desired quality, scale of production, and specific requirements of the project. For instance, flexography is ideal for large-scale industrial printing, while inkjet printing offers cost-effectiveness for small-scale projects. Understanding the unique properties of the plastic film, such as its surface energy and tension, is crucial for achieving high-quality prints with smooth coverage and minimal defects. Proper preparation of the film surface is essential, and treatments like alcohol can be applied to enhance ink adhesion. Selecting the appropriate ink type, such as solvent-based inks or latex inks, is also vital to ensure successful printing on plastic film.
| Characteristics | Values |
|---|---|
| Printing methods | Flexography, pad printing, screen printing, flat-bed printing (inkjet), thermal transfer printer, laser printer, inkjet |
| Inkjet printer suitability | Regular inkjets with water-based inks are not suitable for printing on plastic. Solvent-based inks can be used but are typically used on large-format inkjets. |
| Inkjet printer recommendations | Epson Artisan 1430 Inkjet Printer, Epson print head |
| Inkjet printer cost | $1000 and up for an A4 flat-bed inkjet printer |
| Inkjet printing process | Print art on a sheet of paper, then transfer the image to a plastic substrate using an iron or solvents |
| Flexography printing process | Apply ink on an anilox roller, which works with the doctor blade to control the process of producing an even layer of ink. The roller surface has small cells placed at a particular angle to transfer ink onto the image carrier wrapped around a rotating cylinder. |
| Surface tension | Affects the wettability of ink on the surface. For a successful print, the surface tension of the ink must be lower than the image carrier's. |
| Surface energy | The surplus energy at the surface of the plastic substrate compared to its size. It's important to know its surface energy to avoid costly and time-consuming printing defects. |
| Ink-substrate interaction | Good ink-substrate interaction results in smoother coverage, less pinholes, and fewer printing defects. |
| Surface tension and wettability | Choose inks with surface tension that’s 10 dynes lower than the surface energy of the plastic film to ensure good wettability and high-quality prints. |
| Surface tension adjustments | Adding alcohol or other treatments can affect the surface tension of the ink, but treating the plastic film is more effective. |
| Flexo printing recommendations | Use in-the-round flexo sleeves that are engraved at 100% on size to achieve zero distortion. Elastomer blend sleeves are more durable and flexible than photopolymer plates. |
| Plastic film applications | Labels, food packaging, lidding, sealing, indoor signage, general graphics, outdoor applications |
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What You'll Learn
Flexography printing
The flexography printing process involves six main stages. Firstly, the printing plates, usually made from soft rubber or flexible photopolymer, are prepared with the desired image or text. Each colour in the design requires a separate plate, and the mounting process must be meticulous to ensure precise colour alignment. The plates are then wrapped around rotating cylinders, with only the raised areas of the plate inked.
Next, the ink is supplied to the printing press through ink chambers or rubber rollers. Anilox rollers, with their pattern of tiny cells, control the ink application by carrying and delivering a precise amount of ink to the plate surface. This ensures consistent and sharp prints. The inked plates then transfer the image or text onto the substrate, which is usually in the form of rolls of paper or plastic film. The pressure applied between the plate and the substrate enables the effective transfer of ink, creating a highly precise final print.
Finally, the ink must undergo a drying or curing process to become permanent. This can be achieved through air drying or by using drying systems such as hot air, infrared, ultraviolet (UV), or LED UV technologies. The choice of drying method depends on the ink type and the requirements of the final product.
When printing on plastic film with flexography, it is important to consider the surface tension of the ink and the surface energy of the plastic film. The surface tension of the ink must be lower than that of the image carrier to ensure proper transfer. Choosing inks with a surface tension that is 10 dynes lower than the surface energy of the plastic film will result in smoother coverage and fewer printing defects.
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Inkjet printing
There are a few things to keep in mind when using an inkjet printer for printing on plastic film. Firstly, make sure that the printer's utilities and drivers are installed on the computer, and that the desired image or file is open and ready for printing. Secondly, prepare the plastic film by inserting it into the manual feed paper slot or the printer paper tray, with the rough or sticky side facing the printing side and the lined edge facing the inside of the printer. If the plastic film is very thin, place it on a sheet of paper and secure it with tape on all sides and edges.
In the print menu, select the following options: Paper type: Transparency, Output tray: manual paper feed or tray 1, Quality: Normal or Best (select "Best" for photos), and Borderless printing: Off.
Once the printing is complete, carefully remove the plastic sheet from the printer by lifting it from the sides, being careful not to touch the ink. Allow the print to dry in a cool, dry place for at least fifteen minutes. Even after drying, the ink may still smudge if rubbed hard or folded. To stack the prints, place a sheet of regular paper between each print and avoid placing anything heavy on top.
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Screen printing
The first step in the process is to create a screen frame. This typically involves stretching a fine nylon or polyester mesh tightly over a wooden or metal frame. Next, a layer of photosensitive emulsion is applied evenly to the screen. Once exposed to light, the emulsion hardens, while the unexposed areas remain soft and can be washed away with water.
The prepared design pattern, usually a black design on a transparent film, is then placed over the screen coated with the photo emulsion and exposed to light. This process transfers the visual information/image onto the plastic product.
The specific type of ink used is important. Inks with lower surface tension than the surface energy of the plastic film allow for better wettability and higher-quality prints. The durability of the ink is also important to consider, especially if the printed design will be subjected to rough environments or wear and tear. After the ink dries, a thin layer of varnish can be sprayed onto the surface to improve brightness and protect the ink layer.
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Thermal transfer printing
There are two primary types of thermal printing: direct thermal and thermal transfer. Direct thermal printing involves using heat to cause a chemical reaction in a heat-sensitive material, resulting in an image. This method is often used for printing labels and receipts. The image is printed onto a heat-sensitive material, such as thermal paper, and then transferred to the desired surface using heat and pressure. The heat causes the ink to vaporize and permeate the surface, creating a permanent, high-quality print.
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Surface tension and energy
Printing on plastic film requires an understanding of surface tension and energy. Surface tension is a force in liquids that causes them to act as if surrounded by an elastic membrane. This occurs due to the cohesive forces between liquid molecules, resulting in a net force of zero for molecules away from the surface. However, molecules at the surface experience inward pull, creating internal pressure and causing the liquid to contract to its minimum area. Surface tension gives liquids their near-spherical shape when formed into droplets, as this minimizes the necessary "wall tension".
The concept of surface tension is closely related to surface energy. While surface tension typically refers to liquids, and surface energy to solids, they represent the same underlying phenomenon. Surface energy is the attractive force between molecules at the surface of a solid, holding the substance together. It is the work done per unit area to create a new surface and is measured in joules per square meter.
In printing on plastic film, the interaction between ink and the plastic substrate is crucial for high-quality prints. The surface tension of the ink must be lower than that of the plastic film to ensure proper transfer and adhesion. This can be achieved by selecting the appropriate ink and treating the plastic film. Understanding the surface energy of the plastic substrate is vital to avoid printing defects and ensure optimal results.
The relationship between surface tension and energy extends beyond printing. In manufacturing, knowledge of surface energy allows for predicting how substances will interact and for controlling chemical processes. It helps optimize procedures and set standards, enhancing efficiency and consistency in product quality. Furthermore, surface tension and energy play a role in everyday phenomena, such as the beading of rainwater on a waxy surface or the capillary action that draws liquid up a narrow tube.
By comprehending the principles of surface tension and energy, we can better manipulate and control the behaviour of liquids and solids, leading to advancements in various applications, including printing technologies and manufacturing processes.
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Frequently asked questions
Flexography is one of the most foolproof methods used to print on plastic film substrates. This method involves applying ink to an anilox roller, which works with a doctor blade to control the process of producing an even layer of ink.
Surface tension is a force in liquids that allows them to act as if surrounded by an elastic membrane. It occurs when the molecules of the liquid adhere to one another, causing a beading effect. For successful printing, the surface tension of the ink must be lower than that of the image carrier to ensure proper transfer.
The type of ink depends on the printing method and the properties of the plastic film. Solvent-based inks are suitable for large-format inkjets and provide a waterproof and scratch-proof print. Latex inks are also available for larger format inkjets. Traditional methods may use hardcoats to protect the surface from chemicals and abrasions.
The preparation method depends on the type of plastic, ink type, post-processes, and final application needs. It's important to understand the specific considerations of your project, such as how the product will handle heat and cutting. Treating the plastic film can help ensure good wettability and high-quality prints.
