Maya Ellison
Corrugated plastic, also known as Coroplast, Corflute, Correx, and Corriboard, is a cost-effective, durable, and weather-resistant material used for both indoor and outdoor signage. It is commonly used for business promotions, events, real estate, elections, and more. With its lightweight and customizable properties, it is an ideal substrate for screen printing. Screen printing on corrugated plastic involves using a screen as a substrate and a photosensitive plate-making method to produce a screen that can print a large number of the same graphics. This method offers a cheap and simple printing process but may not be suitable for complicated graphics. Before printing, it is essential to select the appropriate equipment, determine the size of the corrugated plastic sheet, and prepare the required materials, such as inkjet printers, thermal transfer equipment, and cutting tools.
| Characteristics | Values |
|---|---|
| Materials | Corrugated plastic, also known as Coroplast, Corflute, Correx, PP corrugated, PP hollow, and polypropylene corrugated. |
| Printing Methods | Inkjet printing, thermal transfer printing, sticker printing, vinyl printing, and screen printing. |
| Advantages | Lightweight, economical, practical, foldable, durable, weather-resistant, simple printing process, and suitable for both indoor and outdoor use. |
| Disadvantages | Screen printing may not be suitable for complex graphics and can be prone to falling off. |
| Printing Equipment | Inkjet printer, thermal transfer equipment, label stickers, cutting tools, screen printing press, platen, vacuum platen, wooden platen, screen, scoop coater, squeegee, emulsion, and ink. |
| Printing Process | Determine the size of the corrugated plastic based on the amount of information and choose the appropriate printing equipment. Prepare the materials, including the panels, equipment, and stickers or vinyl graphics. For screen printing, coat the emulsion, apply pressure, and expose the screen before printing. |
| Customization | Corrugated plastic signs can be customized in terms of size, shape, and design. They can be cut, mounted, grommeted, and hung to fit specific requirements. |
| Applications | Commodity packaging, logistics transportation, warehousing signs, road signs, real estate signs, elections, promotions, retail signage, and directional signs. |
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What You'll Learn
Printing equipment
When it comes to printing equipment, there are several options to consider for corrugated plastic printing. The most common methods are inkjet printing, thermal transfer printing, and screen printing.
Inkjet printing involves using an inkjet printer to spray patterns or text directly onto the corrugated plastic. This method is simple, convenient, and suitable for small-batch production. Inkjet printers are readily available in various sizes, making it easy to select the appropriate size for your specific needs.
Thermal transfer printing, on the other hand, requires the use of thermal transfer equipment to print patterns or text onto a heat transfer film. The film is then placed onto the corrugated plastic, and the pattern or text is transferred using heat pressing. This method is excellent for high-volume production and can achieve high-quality prints.
Screen printing, a popular choice for printing Coroplast signs, requires the use of a screen printing press. A platen is added to the press, ensuring it is large enough to hold the standard 18x24 corrugated plastic sheet. A vacuum platen is highly effective for this purpose, as the suction keeps the sign flat and in place. A wooden platen can also be used, but it requires the application of spray tack to hold the sign securely. It is important to note that graphic inks typically used in screen printing only allow for one colour to be printed at a time.
Additionally, when using screen printing, a screen that is large enough to accommodate the design is necessary. An aluminium 23x31 screen is often sufficient. The mesh count of the screen is crucial, with solvent-based 'graphic' inks requiring a 200 to 230 mesh screen due to their thin consistency.
For screen printing, specific tools such as a scoop coater, squeegee, and emulsion are required. The choice of emulsion is vital, with graphic emulsions being solvent resistant, allowing for the use of harsher chemicals needed to clean solvent-based inks. Baselayr Long-Lasting Emulsion is a recommended option for those using solvent-based inks.
While screen printing can be a cost-effective option, it may not be suitable for complex graphics as the prints can easily fall off. For intricate designs, UV printing is a better choice, offering a more durable and artistic finish.
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Inkjet printing
To begin the inkjet printing process, you will need to select the appropriate printing equipment based on the desired size and printing effect. Determine the size of the corrugated plastic sheet by considering the amount of information you need to display. If you require more space for text or graphics, opt for a larger sheet. It's also crucial to be mindful of the size limitations of corrugated plastic sheets to decide if you need to cut the material.
For inkjet printing on corrugated plastic, gather the necessary materials, including a suitable inkjet printer, coroplast panels, label stickers (if needed), and cutting tools. Design your signage using software or online tools, ensuring it aligns with your desired information and style.
After designing, create a template by printing or drawing your design on paper, matching the appropriate size and proportions. This template will serve as a guide for making the signage. Choose the inkjet printing method based on your specific requirements and equipment capabilities.
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Thermal transfer printing
The thermal transfer printing process involves three main components: a non-movable print head, a carbon ribbon (the ink), and the substrate. The print head contains heating elements that correspond to its printing resolution. When fired, these heating elements transfer heat through the ribbon and onto the substrate. This, combined with pressure, completes the printing process by transferring the melted ink to the substrate. The ribbon is typically made of wax, resin, or a wax-resin compound, and the choice of ribbon depends on the project as each produces a different print quality.
When it comes to printing on corrugated plastic, thermal transfer printing can be used to achieve high-quality pattern printing, making it suitable for high-volume production. The process involves using thermal transfer equipment to print patterns or text on a heat transfer film. This film is then placed with the corrugated plastic, and the pattern or text is transferred by heat pressing.
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Sticker printing
Corrugated plastic is a versatile material used for various applications, including packaging, transportation, signage, and promotions. It is lightweight, durable, water-resistant, and economical, making it a popular choice for businesses and individuals alike. When it comes to printing on corrugated plastic, there are several methods available, each with its advantages and considerations. Here, we will focus on sticker printing as a method for customising corrugated plastic.
To get started with sticker printing, you will need to gather the necessary materials. This includes purchasing blank coroplast panels, label stickers, and optional cutting tools. It is also essential to consider the printing equipment you will be using, such as an inkjet printer or thermal transfer equipment. The type of equipment will impact the size and printing effect, so choosing the right equipment for your specific needs is crucial.
Once you have the required materials, you can begin designing your stickers. You can use design software or online tools to create a customised design that meets your specific requirements. It is important to ensure that your design is appropriately sized and proportioned to fit the corrugated plastic sheets. After finalising your design, you can print or draw it on paper to create a template that will guide the placement of stickers on the corrugated plastic.
The next step is to print your designed stickers using the chosen printing method and equipment. Ensure that the stickers are printed clearly and accurately, paying attention to factors like colour accuracy and resolution. After printing, carefully cut and process the stickers to ensure they meet the required size and shape specifications. Finally, you can install the stickers onto the blank corrugated plastic sheets, creating a professional and cohesive final product.
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Screen printing
Next, prepare the necessary materials, including coroplast panels, printing equipment such as an inkjet printer or screen printing machine, label stickers (optional), and cutting tools. If screen printing, you will also need a screen, squeegee, emulsion, and ink. The screen should be large enough to accommodate the design, and a higher mesh count is recommended for thinner inks.
For screen printing, begin by coating the screen with the correct emulsion, applying pressure, and pulling the scoop coater upwards, starting with the print side and turning to the squeegee side. Allow the screen to dry with the print side down, and then expose it. Exposure times vary depending on the equipment and materials used, so it is recommended to do a step wedge test to determine the proper exposure time.
Once exposed, you are ready to print. Use an ink suitable for corrugated plastic, such as corrugated plastic ink, which dries at room temperature within 30 minutes. You can speed up the process with a fan. When printing, ensure you print against the flute, allowing the ink to go into the recess, and be careful not to use too much pressure to avoid spreading.
The advantage of screen printing on corrugated plastic is its low cost and simplicity. However, it may not be suitable for complex graphics, as the image may need to be simple to maintain quality. For more intricate designs, UV printing is recommended.
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Frequently asked questions
Corrugated plastic, also known as Coroplast, Corflute, Correx, PP corrugated, PP hollow, and polypropylene corrugated, is a lightweight, durable, and inexpensive material used for signage.
Screen printing on corrugated plastic is a simple, cost-effective way to produce a large number of the same graphic. It is also versatile and suitable for both indoor and outdoor use.
You will need a screen printing press with a platen large enough to hold the corrugated plastic sheet, as well as a screen, scoop coater, squeegee, and emulsion.
First, coat the screen with the correct emulsion and let it dry. Then, expose the screen and print using the appropriate ink for corrugated plastic, such as corrugated plastic ink or solvent-based graphic inks.
You can find a local sign supply store or a company like FedEx Office that offers corrugated plastic printing services.
