Sofia Martinez
There are several methods to transfer images to plastic for industrial use, each with its own advantages and limitations. The most commonly used method is the dye diffusion thermal transfer (D2T2) method, which offers photographic quality images on plastic substrates. This process involves using heat to transfer dyes from a donor ribbon directly into the plastic substrate, allowing for the reproduction of full-colour images with 16.7 million colours. Another method is the dry transfer decal method, which is perfect for semi-permanent applications such as logos and letters. This method provides clean and concise results, making it ideal for prototypes and photoshoots. Other methods include the use of gel mediums and packing tape to transfer images, which can create a vintage aesthetic. The choice of method depends on factors such as volume, time to market, number of colours, and end use of the product.
| Characteristics | Values |
|---|---|
| Method | Dye diffusion thermal transfer (D2T2), dry transfer decals, heat transfer |
| Image Source | Magazine, book, laser printer, photocopier |
| Image Type | Photographic, barcode, text, logo |
| Application | Cards, 3D objects, medical tubes, packaging, promotional products, prototypes |
| Advantages | Quick, dependable, automation-friendly, cost-effective, high quality, durable |
| Disadvantages | Mass transfer images have lower quality than dye diffusion images |
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What You'll Learn
Dye diffusion thermal transfer (D2T2)
The D2T2 process allows for 256 shades of each component colour, with each colour capable of being blended with the other two. This results in a large colour gamut of 16.7 million colours, enabling continuous tone images. This method can produce photographic-quality images within 15-60 seconds.
D2T2 printing is not limited to digital photographs on plastics but is also used for printing on PVC cards, such as ID cards, driving licences, visitors' passes, and loyalty cards. The process is recognised as a Non-Impact Printing (NIP) method, finding major uses in security, medical, scientific, and novelty markets.
D2T2 offers higher-quality images compared to mass transfer images, which have a dot pattern rather than a continuous tone. However, mass transfer allows the use of dyes and pigments that may not transfer from the ribbon to the substrate or diffuse from one polymer matrix to another.
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Pad transfer
Pad printing, also known as tampo printing or tampography, is a printing process that uses a silicon pad and a printing plate. It is an indirect offset process that can be used on various product shapes, such as curved, hollow, or other complex surfaces. It is also suitable for all kinds of textures and angles, making it a versatile printing option.
The process of pad printing involves creating a printing plate, also known as a "cliche," etched with the desired image, symbols, or letters. This plate can be made using photopolymer or laser processes. The ink cup, or ink-transfer mechanism, then applies ink to the etching by sliding across the print plate and depositing a controlled amount of ink, a process known as "doctoring." The ink cup has a ring, which can be made of ceramic, metal, or plastic, to regulate ink flow.
The silicon pad, adaptable to the shape of the object, then picks up the image from the inked etching and transfers it to the desired surface. Pad printing inks are formulated to match the material being printed on, with options available for various plastic materials such as ABS, Acrylic, HIPS, polycarbonate, and nylon. Pre and post-treatment procedures can also enable printing on more challenging materials.
Pad printing is widely used across industries, including medical, cosmetic, electronic, and automotive. It is ideal for adding intricate details to small surfaces, such as barcodes, logos, and labels, and can be applied to delicate products that may break with other printing methods. Pad printing is also suitable for various textures and shapes, making it a flexible method for plastic injection molding.
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Dry transfer decals
Step 1: Prepare the Surface and the Decal
Ensure your work area is clean, dry, and free of dust and moisture. Clean the surface with a mild cleaner to remove any grease or fingerprints. If the surface is electronic, ensure it is also free of static. Cut out the dry transfer decal from the plastic sheet, leaving a small margin or border around the design.
Step 2: Position and Apply the Decal
Visually centre and align the decal, then lightly push down on the image to secure it in place. If the transfer has a large area, hold the top corner to stabilize it. Use your finger or a burnishing tool to firmly rub over the entire surface of the transfer, applying even pressure and moving from the centre outward to avoid bubbles and ensure full adhesion.
Step 3: Remove the Backing and Inspect
After rubbing the transfer thoroughly, slowly and carefully peel off the backing paper from one corner, maintaining a sharp angle to avoid lifting the transfer. Inspect the transfer to ensure all parts have adhered properly. If any areas have not adhered, lay the backing down and rub over that area again.
Step 4: Finalize and Protect
Once the decal is fully transferred, give it a final, gentle rub with your finger to ensure all parts are stuck down well. For added protection and durability, especially on frequently handled items, apply a clear coat of varnish, sealant, or clear coat over the decal once it is fully dry.
With these steps, you can successfully apply dry transfer decals to various surfaces, creating intricate and detailed designs with a professional and seamless finish. Practice and patience are key to mastering this process.
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Heat transfer
In the context of printing on plastic, heat transfer printing is commonly used in plastic bucket manufacturing to apply designed graphics, logos, bar codes, and textures onto plastic pails or buckets. This process involves using a special printer to print the design on heat transfer paper with inks made specifically for printing on plastic, such as sublimation ink or pigment ink. The PET film is then applied to the plastic surface using heat and pressure, with the recommended temperature set between 350 and 375°F (177 to 191°C). The pressure applied depends on the thickness of the plastic, with softer plastics requiring less printing press.
The dye diffusion thermal transfer (D2T2) method is another heat transfer printing technique used to print photographic-quality images onto plastic substrates. This process uses heat to promote the diffusion of dyes from a dye donor ribbon directly into the plastic substrate, allowing the dyes to penetrate materials such as polyesters and polyvinyl chloride (PVC). Each of the three coloured dyes (yellow, magenta, and cyan) is transferred sequentially, and the image is protected by thermally transferring another polymer on top. This method can produce 16.7 million colours, resulting in continuous tone images and photographic-quality prints within 15-60 seconds.
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Using gel medium
Firstly, you will need a few supplies: a gel medium (any clear acrylic medium works), a brush, a dish or tray, water, scissors, and an image to transfer. Any image can be used for transferring, although some work better than others. Uncoated magazines and newspapers work beautifully, but more coated photos and postcards may or may not transfer well. Laser-printed images work, but inkjet prints generally do not.
Next, spread an even coat of the gel medium on the underside of the image and press it firmly onto the plastic surface. You may wish to add an extra coat on top to smooth out any curly edges. You can now alter your work as you please.
Allow the application to dry completely. When the application is dry, dampen the paper with a wet sponge. Give it a few minutes to allow the water to penetrate the paper pulp. Begin rubbing carefully to remove the paper but leave the image intact in the gel medium. You will probably have to dampen the paper a few times for a clean transfer.
After carefully scrubbing off all of the paper fibres from the gel, give it one final rinse in fresh water to remove any remaining paper residue and allow it to dry. Note that it is normal for the gel to still appear milky, and it will not completely clear until dry. After drying, you're left with the transferred image on the plastic.
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