Industrial Printing 101

An Introduction to Printing

 

Digital Printing

Digital printing is a versatile range of printing methods that directly transfer inks from a digital file onto the substrate. This eliminates the need for plates or films, making it ideal for short runs and customisation. It's widely used for personalised products, packaging, and on-demand printing across retail and automotive sectors.

Benefits

  • Fast turnaround times.
  • High-quality output.
  • Ideal for customisation and short runs.
  • Durability (UV).
  • Consistent color.
  • Good color intensity.
  • Lower cost.
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Products

From automotive applications to graphic user interface items and packaging.

Applications

Printing of unique/variable alpha numeric, 2D, and QR codes for track and trace and brand protection.

Flexographic Printing

Flexography uses flexible photopolymer plates and a solvent-based or water-based ink system. This printing process is well-suited for printing on flexible materials like plastic films, paper, and non-woven fabrics.

Benefits

  • Versatile for various substrates.
  • Suitable for high-volume production.
  • Cost-effective for large quantities.

Products

From product identification labels to specialised applications like regulatory and compliance labelling, battery labels, VIN labels, and more, flexographic printing offers a versatile and efficient solution.

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Screen Printing

Rotary Screen Printing

Rotary Screen Printing is a high-volume printing technique using a cylindrical screen with a mesh pattern. The mesh allows ink to pass through to the substrate, creating the complex designs, particularly effective for large-scale production of textiles, FMCG goods and packaging, including clear containers or window graphics and products focused on creating a strong tactile effect.

Benefits of Rotary Screen Printing

  • Ideal for large quantities of printed products.
  • Uniform color and design.
  • Produces bold and vivid hues.
  • Intricate patterns and details.
  • Suitable for a wide range of materials and applications.
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Flatbed Screen Printing

With Flatbed Screen Printing, a squeegee pushes ink through the screen (stencil) onto the substrate. Ink passes through areas of the screen that have not been blocked to create printed pattern. This can be suitable for smaller, irregularly shaped items such as circuit boards and membrane keypads.

Benefits of Flatbed Screen Printing

  • Works across a wide range of substrates, including plastics, glass, metal, and textiles.
  • Durable prints with metallics, vibrant colors and fine details.
  • Can create textured effects or provide added protection.
  • Ability to print on thicker materials.
  • Ability to print conductive traces for electronic applications.

Gravure Printing

Gravure is a high-volume printing process using engraved cylinders to transfer ink directly onto the substrate. The gravure printing process is known for producing high-quality, consistent results with excellent colour reproduction. It can be used on a wide range of substrates, including paper, plastic films, and textiles and is highly efficient for large-volumes, making it suitable for mass production of products. Common commercial applications include packaging, labels, security-related printing, automotive and architectural films.

Benefits

  • High volume applications.
  • Excellent print quality & color management.
  • Good for four color process & soft transition effects.
  • Good for metallic and special coatings.
  • Extremely durable ink chemistry.

Combining Printing Processes

The commercial production of products often involves, not just the combination of a range of manufacturing processes, but a specific combination of printing processes to achieve consistent, premium results for example in CCL Design’s unique adhesive printing processes.

As a trusted partner, CCL Design leverages our global manufacturing capabilities to deliver innovative, high-quality products while improving manufacturing efficiencies and minimising our environmental impact.

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Client Successes

Backlit Display Blues [Case Study]

CCL Design engages a multi-disciplinary team across the globe who collaborate to identify key opportunities to simplify a client's backlit display window module with an innovative design addressing both lighting and structural concerns.

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