Omar Khalid
UV printing on plastic is a process that involves using a UV printer to print patterns, text, and images onto plastic surfaces. This method of printing offers high precision, durability, and vivid colours, making it ideal for various applications such as signage, branding logos, promotional products, and custom toys. Before UV printing on plastics, it is essential to pre-treat the surface to ensure optimal ink adhesion. The level of pre-treatment depends on the intended use and desired longevity of the printed product. Additionally, the choice of printer and ink type plays a crucial role in achieving successful UV printing results on plastic.
| Characteristics | Values |
|---|---|
| Plastic types | Polyethylene Terephthalate (PETE or PET), High-Density Polyethylene, Polyvinyl Chloride, Low-Density Polyethylene, Polypropylene, Polystyrene or Styrofoam, miscellaneous plastics like polycarbonate, acrylic, styrene, fiberglass, nylon, polylactide, and Tritan |
| Printing techniques | UV flatbed printer, digital cylindrical printer, Mimaki UJF 6042, PRISMA Z-Max, SUBLISTAR UV direct printing technology, UV DTF printing technology |
| Pre-treatment methods | Primer wipe, flame, corona, plasma, PYROTRACK System |
| Adhesion testing | Tape, scratch, Crosshatch A, Crosshatch B, flexible bottle and ice bucket testing |
| Inks | T2 UV Ink in Cyan, Magenta, Yellow, Black, White, and Varnish |
| Applications | Drinkware, promotional products, signage, branding logos, marketing products, toys, stationery, awards, plastic sheet stock |
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UV printer options
UV printing is a versatile technology that can be used to print full-colour graphics and images onto a wide range of materials and substrates. UV printers use UV ink and built-in UV lights to cure inks directly onto surfaces, including plastic, wood, metal, acrylic, crystal, glass, fabric, foam boards, paper, and more.
There are several UV printer options available on the market, with varying features and capabilities. Here are some examples:
- Flatbed UV Printers: These printers can handle a range of materials, from flexible fabrics to rigid boards. They are ideal for printing on flat surfaces and can produce high-quality, durable prints. Flatbed UV printers come in various sizes, from A5 for phone case printing to large A3+ industrial-scale printers for mass production.
- Digital Cylindrical Printers: These printers are suitable for printing on cylindrical objects, such as bottles or cups, and can achieve stunning, full-colour graphics.
- Roland DG Printers: Roland DG offers a range of UV printers known for their flexibility and fast turnaround times. Their printers can handle most fabrics and flatbed materials, and they are commonly used for promotional goods and product decoration.
- Procolored UV Printers: Procolored offers UV flatbed printers in diverse sizes, from A4 and A3 for decor printing to larger A1 printers for lawn sign or advertising board printing. They also provide UV DTF printers recommended for printing on hard substrates.
- EufyMake E1 UV Printer: A more affordable option for those looking to explore UV printing at home. It can accommodate three-dimensional objects and provides high-resolution colour images.
When choosing a UV printer, it is essential to consider the specific materials you plan to print on, the desired print quality, and the volume of printing required to make an informed decision that aligns with your needs.
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Pre-treatment methods
UV printing on plastic requires pre-treatment to ensure optimal adhesion. The level of pre-treatment depends on the intended life of the product. For instance, a promotional product requires a lower level of pre-treatment than drinkware.
There are several pre-treatment methods available, including primer wipes, flame, corona, or plasma pre-treatments. A primer wipe alone can satisfy the needs of a promotional product's lifespan. Inkcups offers four primers specifically for plastic: XF Primer, S Primer, PP Primer, and PL Primer. The PP Primer, for example, reduces the surface tension on Polypropylene and Polyethylene products for better adhesion.
For plastic drinkware, it is recommended to first treat with a primer wipe and then with either a flame, corona, or plasma pre-treatment. Corona treatment can be done with a corona treatment machine. Alternatively, a flame treatment can be used, as some have done with success when printing on glass.
For Tritan plastic, which is typically difficult to adhere ink to, Inkcups offers T2 UV Ink, which does not require a pre-treatment process and provides excellent adhesion and high abrasion resistance.
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Adhesion testing
The tape test involves applying tape to the printed surface and then removing it to check if the ink adheres properly. The scratch test uses a sclerometer, which resembles a pen, and is dragged across the printed surface. This test fails if any ink is lifted or if a jagged line remains. Crosshatch A involves using a razor blade to make an X-cut on the substrate, followed by the tape test. For Crosshatch B, a lattice pattern is cut into the printed surface, and it must score a 5 to pass, indicating that all squares of the lattice remain intact.
The choice of substrate and its intended use, such as promotional purposes or drinkware, determines the pre-treatment method and primer selection. For example, drinkware requires stronger adhesion due to frequent washing, whereas a candle holder may not need the same level of adhesion. Inkcups offers four primers designed for plastic: XF Primer, S Primer, PP Primer, and PL Primer. The PP Primer is notable for improving the bond between Polypropylene and Polyethylene products.
When choosing a UV ink, it is essential to consider the substrate and select an ink that adheres well to the specific material. For instance, T2 UV ink is suitable for Tritan plastic, a popular choice for drinkware due to its BPA-free composition, while other UV inks like S1 UV Inkjet ink, XFlexx, and BB Ultra Flexible UV ink are options for plastics in the promotional and industrial sectors.
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Ink types
When it comes to ink types for UV printing on plastic, there are a few options to consider. Firstly, it's important to choose an ink that adheres well to the specific type of plastic being printed on. This is essential to ensure that the print doesn't scratch or peel off easily. Inkcups offers four primers specifically for plastic: XF Primer, S Primer, PP Primer, and PL Primer. PP Primer, for instance, is effective in reducing the surface tension on Polypropylene and Polyethylene products, allowing for a stronger bond.
For printing on plastics like Tritan, which is known for its safety and lack of BPA, BPS, and other bisphenols, a pre-treatment process is typically required for successful ink adhesion. However, Inkcups offers T2 UV Ink, which can be used with their cylindrical or flatbed printers to print on Tritan plastic without the need for pre-treatment. T2 UV ink comes in Cyan, Magenta, Yellow, Black, White, and Varnish, allowing for vibrant graphics with excellent adhesion and abrasion resistance.
Another option to improve ink adhesion is to use a primer wipe followed by a flame, corona, or plasma pre-treatment. This combination can effectively prepare the plastic surface for better ink adhesion. Additionally, adhesion promoters can be used, especially when printing on glass, to improve the bonding between the ink and the plastic surface.
It's worth noting that the level of pre-treatment and choice of ink depend on the intended use and lifespan of the product. For example, promotional products may require less adhesion strength compared to drinkware that needs to be dishwasher-safe. ASTM provides four standardized tests (Tape, Scratch, Crosshatch A, and Crosshatch B) to ensure the correct pre-treatment methods and ink are used for optimal adhesion.
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Plastic types
There are seven different types of plastic that can be used for UV printing. These include:
Polyethylene Terephthalate (PETE or PET)
This type of plastic is commonly used for manufacturing items such as food packaging, beverage bottles, and other containers. It is known for its lightweight yet durable properties.
High-Density Polyethylene
High-Density Polyethylene, often abbreviated as HDPE, is a versatile plastic used in a wide range of applications, including plastic bags, containers, and bottles. It is known for its high strength and stiffness.
Polyvinyl Chloride (PVC)
PVC is a widely used plastic known for its durability and versatility. It is commonly used in construction materials, such as pipes and wiring, as well as in packaging and clothing.
Low-Density Polyethylene (LDPE)
LDPE is a flexible and lightweight type of plastic. It is often used in plastic bags, film, and packaging materials. LDPE is also known for its good moisture barrier properties.
Polypropylene (PP)
Polypropylene is a versatile plastic with excellent chemical resistance and heat stability. It is commonly used in packaging, textiles, automotive parts, and reusable food containers. PP is also suitable for UV printing, but it may require additional treatments to improve ink adhesion.
Polystyrene (PS) or Styrofoam
Polystyrene is a lightweight and inexpensive plastic commonly used for packaging and insulation. It is often used for food packaging and disposable cups or containers.
Miscellaneous Plastics
In addition to the above, there are various other plastics that can be used for UV printing, including polycarbonate, acrylic, styrene, fiberglass, nylon, and polylactide. Each of these plastics has unique properties and applications, and they can be used to create a wide range of products, from signage and branding materials to car parts and reusable drinkware.
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Frequently asked questions
UV printing on plastic is a process that uses UV light to cure ink, resulting in high-quality, full-colour graphics that are durable, vivid, and efficient.
UV printing avoids the complex plate-making process of traditional printing, offering a faster and more efficient product printing effect. It also allows for high-precision printing, ensuring clear and delicate results.
UV printing on plastic is commonly used for promotional products, drinkware, signage, branding logos, marketing materials, and custom designs on toys, stationery, and awards.
Recommended UV printers include the Mimaki UJF 6042, PRISMA Z-Max, and Super Performance UV-6090F Star V Flatbed UV Printer, which offer high-quality printing on various plastic substrates.
Pre-treatment is necessary to ensure optimal ink adhesion. This includes using a primer wipe, flame, corona, or plasma pre-treatment, and considering adhesion promoters or primers specific to the type of plastic being printed on.
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