Maya Ellison
Screen printing is a popular method for printing on plastic products. It is a highly specialised process used to print on flat and flexible plastic surfaces, and it is compatible with various types of plastics and inks. The process involves transferring an image or design onto a plastic product using a printing screen. Before printing, it is important to ensure that the plastic substrate is thoroughly cleaned and free of dust, lint, or scratches. It is also crucial to choose the right ink and mesh count for the specific plastic and ink being used.
| Characteristics | Values |
|---|---|
| Printing methods | Gravure printing, flexographic printing, screen printing, anti-counterfeiting printing, jet printing, transfer printing |
| Printing requirements | Screen, squeegee, ink, printing plate, substrate |
| Ink type | Air-dry inks |
| Mesh count | 280 or higher |
| Printing applications | Signs, panels, displays, pipes, boxes, containers, films, fibres, promotional items |
| Printing results | Vibrant, bold, bright, firm, metallic, durable |
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What You'll Learn
- Printing methods: Gravure, flexographic, anti-counterfeiting, jet printing, etc
- Choosing the right ink: Air-dry inks are recommended
- Mesh count: A higher mesh count prevents ink from falling through
- Plastic types: Screen printing is compatible with various types of plastic
- Printing press: The current press may be suitable for plastic applications
Printing methods: Gravure, flexographic, anti-counterfeiting, jet printing, etc
Printing on plastic products includes various methods, such as gravure printing, flexographic printing, anti-counterfeiting printing, jet printing, and screen printing. Each method has its unique characteristics and applications.
Gravure printing, also known as photogravure, is a variation of engraved-cylinder gravure printing. It involves using photographic methods to etch copper plates, which are then wrapped onto cylinders. This process is more cost-effective for shorter runs of high-quality printing, commonly used for reproducing high-end art prints with a wide range of subtle shades. Gravure printing is primarily used for long print runs.
Flexographic printing, often referred to as flexo printing, is a highly precise process ideal for detailed and high-quality work on various substrates. In flexo printing, ink is supplied to the printing press through ink chambers or rubber rollers, with anilox rollers controlling the ink application for consistent and sharp prints. The substrate, typically in the form of rolls of paper or plastic film, is then fed into the printing press, where the inked plates transfer the desired image or text. After printing, the ink must undergo a drying or curing process to become permanent.
Anti-counterfeiting printing methods aim to combat the serious harm caused by fake and inferior products. These methods often involve adding special materials or using professional detection equipment to create unique and difficult-to-forge patterns. However, these approaches can be costly and complicated for consumers to verify. As a result, there is a growing focus on using the printing characteristics of anti-counterfeiting patterns without adding additional security features.
Jet printing, or inkjet printing, has seen extensive development since its inception in the 20th century. Inkjet printers use two main technologies: continuous (CIJ) and drop-on-demand (DOD). CIJ involves a continuous stream of pressurized ink, while DOD expels ink from the nozzle one drop at a time through mechanical or electrical means. Inkjet printing is versatile, with applications in decorating baked goods, forming conductive traces for circuits, and creating biosensors for tissue engineering.
Screen printing on plastic products involves transferring visual information or images onto a plastic product using a screen. The five major elements of screen printing are the screen, squeegee, ink, printing plate, and substrate. The ink is scraped through the screen mesh onto the plastic substrate to create the desired image.
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Choosing the right ink: Air-dry inks are recommended
When it comes to choosing the right ink for screen printing on plastic, air-dry inks are recommended. This is because plastic can warp or melt under extreme heat, so it's best to avoid flash units or conveyor dryers. Air-dry inks are a convenient option as they dry in the air, eliminating the need for such equipment. However, it's important to let each colour dry completely before moving on to the next one if you're creating a multicoloured design. Remember to reclaim your screens promptly after printing to prevent ink curing on them.
Air-dry inks for plastic printing typically have a higher mesh count, usually 280 or higher. This higher mesh count ensures that the ink doesn't fall through the screen and ruin your printing project. Before you begin printing, it's crucial to clean the substrate thoroughly to remove any dust, lint, or scratches.
When selecting an air-dry ink, refer to the manufacturer's suggestions to ensure you're choosing the most suitable ink for your specific application. Manufacturers can also advise on any necessary additives to ensure proper curing and adhesion to your substrate. Some air-dry ink products, such as ColorFX, include a retarder and reducer.
Using a higher mesh count screen is generally recommended when printing with air-dry inks on plastic. This helps prevent ink from falling through the screen and maintains the quality of your print. Additionally, consider the storage space required for items printed with air-dry inks, as they need ample space to cure fully. For example, you may need a drying rack for larger items like yard signs.
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Mesh count: A higher mesh count prevents ink from falling through
Mesh count is a measure of how many threads of polyester cross each other per square inch on a screen. The higher the mesh count, the finer the threads and holes in the screen. This is important because the mesh count determines how much ink is deposited onto the substrate. For example, a 110 mesh count screen lays down a fairly thick layer of ink and is great for printing block letters and larger spot-color designs. On the other hand, a 156 mesh count screen lays down a thicker layer of ink but with higher detail, making it the go-to screen for many printers.
When printing on plastic, the mesh count will depend on the level of detail in the design and the thickness of the ink used. For images with high detail, a higher mesh count screen should be used because the fine dots of detail will fall through the holes in low mesh count screens. Thinner inks, like water-based inks, should also be printed through a high mesh count to prevent them from blurring the image by flooding through the larger holes in low mesh count screens.
For printing on plastic with thinner inks and high detail, a mesh count of around 230 is recommended. This mesh count can hold large halftone dots and is suitable for graphic and solvent-based screen printing inks. If you are using a four-color printing process, a higher mesh count is also recommended. A 305 mesh count, for example, is great for getting extremely high detail.
However, it is important to note that printing through a high mesh count creates a softer feel since less ink passes through the screen. As a result, the print may look distressed due to the thin ink deposit. For vibrant prints on plastic, a lower mesh count should be used to allow for a higher ink deposit. For solid white text on a black background, for example, a low mesh count is recommended to allow for more ink flow and a more opaque result.
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Plastic types: Screen printing is compatible with various types of plastic
Screen printing is compatible with various types of plastic, each offering unique advantages and applications. The effectiveness of the printing process depends on the properties of the plastic, such as its dyeability, colourfastness, surface texture, hardness, and shape. Here are some common types of plastic suitable for screen printing:
Polyvinyl Chloride (PVC)
PVC is favoured for its bright colour, anti-break properties, acid and alkali resistance, and cost-effectiveness. However, caution is necessary due to potential toxicity from added materials during production, making it unsuitable for food containers.
ABS Resin Plastic
ABS resin plastic is known for its applications in televisions and calculators. It stands out for its easy processability and forming capabilities. ABS plastic is commonly used for keyboard manufacturing due to its glossy appearance, low water absorption, impact strength, and surface hardness within a specific temperature range.
Polyethylene Plastics
Polyethylene plastics are widely used and versatile. They can be transformed into various products through processes like extrusion and injection moulding.
Polypropylene
Polypropylene is suitable for diverse moulding methods and can be processed into pipes, boxes, containers, films, fibres, and more. It exhibits high spatial regularity, crystallinity, and melting point characteristics.
It is important to note that not all plastics are alike, and some may have smooth or uneven surfaces that affect ink adhesion and print clarity. Proper surface preparation, including cleaning and treating with primers or adhesion promoters, is crucial to ensure successful screen printing on plastic.
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Printing press: The current press may be suitable for plastic applications
Firstly, it is important to consider the properties of the plastic itself, such as its dyeability and colorfastness. Different plastics have varying levels of compatibility with printing methods. For example, ABS plastic is commonly used for keyboard manufacturing due to its glossy appearance, low water absorption, and excellent impact strength.
Secondly, the desired print quality and durability should be considered. Screen printing, pad printing, and laser etching are the most widely used methods for printing on plastic. Screen printing, which involves creating a screen frame, applying a photo emulsion, and exposing a design pattern, is a versatile and cost-effective option. Pad printing, a type of ink transfer printing, is suitable for printing on uneven surfaces and complex shapes. Laser etching, on the other hand, offers high durability but has limitations on uneven or textured surfaces.
Additionally, the curing process is essential for optimal ink adhesion and durability. Thermal curing involves exposing printed items to controlled temperatures, typically between 60°C and 100°C, to trigger a thermal reaction that cures the ink. Higher curing temperatures generally yield better printing results but can also lead to shrinkage and deformation, depending on the plastic material.
By understanding the properties of the plastic, the desired print quality, and the curing process, you can assess the suitability of your current press for plastic applications and make any necessary adjustments or explore alternative printing methods.
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Frequently asked questions
The five major elements of screen printing are the screen printing screen, squeegee, ink, printing plate, and substrate.
Air-dry inks are recommended for printing on plastic because extreme heat can warp or melt plastic. You should refer to your ink manufacturer's suggestions when choosing the right ink for the job.
Screen printing is compatible with various types of plastic and produces bold, bright, firm, and metallic colours that make your designs stand out. It is also much easier to fix mistakes on most plastic surfaces compared to fabric.
