Inkjet printers

Inkjet printers operate by propelling variably-sized droplets of liquid or molten material (ink) onto almost any sized page. They are the most common type of computer printer for the general consumer due to their low cost, high quality of output, capability of printing in different colors, and ease of use.
The inkjet has built on the progress made by many earlier versions. Among many contributors, Epson, Hewlett-Packard and Canon can claim a substantial share of the credit for the development of the modern inkjet. In the worldwide consumer market, four manufacturers account for the majority of inkjet printer sales: Canon, Hewlett-Packard, Epson, and Lexmark
The emerging ink jet material deposition market also uses ink jet technologies, typically piezoelectric jets, to deposit materials directly on substrates.

Textile printing

Textile printing is the process of applying colour to fabric in definite patterns or designs. In properly printed fabrics the colour is bonded with the fiber, so as to resist washing and friction. Textile printing is related to dyeing but, whereas in dyeing proper the whole fabric is uniformly covered with one colour, in printing one or more colours are applied to it in certain parts only, and in sharply defined patterns.
In printing, wooden blocks, stencils, engraved plates, rollers, or silkscreens are used to place colours on the fabric. Colourants used in printing contain dyes thickened to prevent the colour from spreading by capillary attraction beyond the limits of the pattern or design.
Traditional textile printing techniques may be broadly categorised into four styles:
• Direct printing, in which colourants containing dyes, thickeners, and the mordants or substances necessary for fixing the colour on the cloth are printed in the desired pattern.
• The printing of a mordant in the desired pattern prior to dyeing cloth; the color adheres only where the mordant was printed.
• Resist dyeing, in which a wax or other substance is printed onto fabric which is subsequently dyed. The waxed areas do not accept the dye, leaving uncoloured patterns against a coloured ground.
• Discharge printing, in which a bleaching agent is printed onto previously dyed fabrics to remove some or all of the colour.
Resist and discharge techniques were particularly fashionable in the 19th century, as were combination techniques in which indigo resist was used to create blue backgrounds prior to block-printing of other colours. Most modern industrialised printing uses direct printing techniques.

Screenprinting materials

Metallic
similar to glitter, but smaller particles suspended in the ink. A glue is printed onto the fabric then a nanoscale fibers applied on it.
Expanding ink (puff)
an additive to plastisol inks which raises the print off the garment, creating a 3D feel.
Caviar beads
again a glue is printed in the shape of the design, to which small plastic beads are then applied – works well with solid block areas creating an interesting tactile surface.
Four colour process
artwork is created and then separated into four colours (CMYK) which combine to create the full spectrum of colours needed for photographic prints. This means a large number of colours can be simulated using only 4 screens, reducing costs, time, and set-up. The inks are required to blend and are more translucent, meaning a compromise with vibrancy of colour.
Gloss
a clear base laid over previously printed inks to create a shiny finish.
Nylobond
a special ink additive for printing onto technical or waterproof fabrics.
Mirrored silver
Another solvent based ink, but you can almost see your face in it.
Suede Ink
Suede is a milky coloured additive that is added to plastisol. With suede additive you can make any colour of plastisol have a suede feel. It is actually a puff blowing agent that does not bubble as much as regular puff ink. The directions vary from manufacturer to manufacturer, but generally you can add up to 50% suede additive to your normal plastisol.

Screenprinting materials

Plastisol
the most common ink used in commercial garment decoration. Good colour opacity onto dark garments and clear graphic detail with, as the name suggests, a more plasticized texture. This print can be made softer with special additives or heavier by adding extra layers of ink. Plastisol inks require heat (approx. 150°C (300°F) for many inks) to cure the print.
Water-Based inks
these penetrate the fabric more than the plastisol inks and create a much softer feel. Ideal for printing darker inks onto lighter coloured garments. Also useful for larger area prints where texture is important. Some inks require heat or an added catalyst to make the print permanent.
PVC/ Phalate Free
relatively new breed of ink and printing with the benefits of plastisol but without the two main toxic components - soft feeling print.
Discharge inks
used to print lighter colours onto dark background fabrics, they work by removing the dye in the garment – this means they leave a much softer texture. They are less graphic in nature than plastisol inks, and exact colours are difficult to control, but especially good for distressed prints and underbasing on dark garments that are to be printed with additional layers of plastisol.
Flocking
consists of a glue printed onto the fabric and then foil or flock (or other special effect) material is applied for a mirror finish or a velvete touch.
Glitter/Shimmer
metallic flakes are suspended in the ink base to create this sparkle effect. Usually available in gold or silver but can be mixed to make most colours.

Printing technique

A screen is made of a piece of porous, finely woven fabric called mesh stretched over a frame of aluminum or wood. Originally human hair then silk was woven into screen mesh; currently most mesh is made of man-made materials such as steel, nylon, and polyester. Areas of the screen are blocked off with a non-permeable material to form a stencil, which is a negative of the image to be printed; that is, the open spaces are where the ink will appear.
The screen is placed atop a substrate such as paper or fabric. Ink is placed on top of the screen, and a fill bar (also known as a floodbar) is used to fill the mesh openings with ink. The operator begins with the fill bar at the rear of the screen and behind a reservoir of ink. The operator lifts the screen to prevent contact with the substrate and then using a slight amount of downward force pulls the fill bar to the front of the screen. This effectively fills the mesh openings with ink and moves the ink reservoir to the front of the screen. The operator then uses a squeegee (rubber blade) to move the mesh down to the substrate and pushes the squeegee to the rear of the screen. The ink that is in the mesh opening is pumped or squeezed by capillary action to the substrate in a controlled and prescribed amount, i.e. the wet ink deposit is equal to the thickness of the mesh and or stencil. As the squeegee moves toward the rear of the screen the tension of the mesh pulls the mesh up away from the substrate (called snap-off) leaving the ink upon the substrate surface.
There are three types of screenprinting presses. The 'flat-bed' (probably the most widely used), 'cylinder', and 'rotary'.
Textile items are printed in multi-colour designs using a wet on wet technique, while graphic items are allowed to dry between colours that are then printed with another screen and often in a different colour.
The screen can be re-used after cleaning. However if the design is no longer needed, then the screen can be "reclaimed", that is cleared of all emulsion and used again. The reclaiming process involves removing the ink from the screen then spraying on stencil remover to remove all emulsion. Stencil removers come in the form of liquids, gels, or powders. The powdered types have to be mixed with water before use, and so can be considered to belong to the liquid category. After applying the stencil remover the emulsion must be washed out using a pressure washer.
Most screens are ready for recoating at this stage, but sometimes screens will have to undergo a further step in the reclaiming process called dehazing. This additional step removes haze or "ghost images" left behind in the screen once the emulsion has been removed. Ghost images tend to faintly outline the open areas of previous stencils, hence the name. They are the result of ink residue trapped in the mesh, often in the knuckles of the mesh, those points where threads overlap.
While the public thinks of garments in conjunction with screenprinting, the technique is used on tens of thousands of items, decals, clock and watch faces, balloons and many more products. The technique has even been adapted for more advanced uses, such as laying down conductors and resistors in multi-layer circuits using thin ceramic layers as the substrate.

Screen printing

Screen printing is a printing technique that uses a woven mesh to support an ink-blocking stencil. The attached stencil forms open areas of mesh that transfer ink as a sharp-edged image onto a substrate. A roller or squeegee is moved across the screen stencil, forcing or pumping ink past the threads of the woven mesh in the open areas.

Screen printing is also a stencil method of print making in which a design is imposed on a screen of silk or other fine mesh, with blank areas coated with an impermeable substance, and ink is forced through the mesh onto the printing surface. It is also known as "silk screening" or "serigraphy".

Digital printing

Digital printing is the reproduction of digital images on a physical surface. It is generally used for short print runs, and for the customization of print media.
The process differs from lithography, flexography, gravure, and letterpress printing in several ways:
• Every print can be different, because printing plates are not required, as in traditional methods.
• There is less wasted chemical and paper, because there is no need to bring the image "up to colour" and check for registration and position.
• The ink or toner does not permeate the substrate, as does conventional ink, but forms a thin layer on the surface and may in some systems be additionally adhered to the substrate by using a fuser fluid with heat process (toner) or UV curing process (ink).
Because there is less initial setup, it is useful for rapid prototyping, and cost effective for small print runs.
Digital Printing is used for personalized printing, or variable data printing (VDP or VI), for example personalized children's books, which are customized with the specific child's name and images. Print on Demand (POD) systems also use digital printing, for short run books of varying page quantities, and binding techniques.

Process Overview of Flexography

Process Overview
1. Platemaking
The first method of plate development uses light-sensitive polymer. A film negative is placed over the plate, which is exposed to ultra-violet light. The polymer hardens where light passes through the film. The remaining polymer has the consistency of chewed gum. It is washed away in a tank of either water or solvent. Brushes scrub the plate to facilitate the "washout" process. The process can differ depending on whether solid sheets of photopolymer or liquid photopolymer are used, but the principle is still the same. The second method used a computer-guided laser to etch the image onto the printing plate. Such a direct laser engraving process is called digital platemaking. The third method is to go through a molding process. The first step is to create a metal plate out of the negative of our initial image through an exposition process (followed by an acid bath). This metal plate in relief is then used in the second step to create the mold that could be in bakelite board or even glass or plastic, through a first molding process. Once cooled, this master mold will press the rubber or plastic compound (under both controlled temperature and pressure) through a second molding process to create the printing plate.
2. Printing
A flexographic print is made by creating a positive mirrored master of the required image as a 3D relief in a rubber or polymer material. Flexographic plates can be created with analog and digital platemaking processes. The image areas are raised above the non image areas on the rubber or polymer plate. The ink is transferred from the ink roll which is partially immerged in the ink tank. Then it transfers to the anilox roll (or meter roll) whose texture holds a specific amount of ink since it's covered with thousands of small wells or cups that enable it to meter ink to the printing plate in a uniform thickness evenly and quickly (the number of cells per linear inch can vary according to the type of print job and the quality required). To avoid getting a final product with a smudgy or lumpy look, it must be ensured that the amount of ink on the printing plate is not excessive. This is achieved by using a scraper, called a doctor blade. The doctor blade removes excess ink from the anilox roller before inking the printing plate. The substrate is finally sandwiched between the plate and the impression cylinder to transfer the image.
Flexographic printing inks
The nature and demands of the printing process and the application of the printed product determine the fundamental properties required of flexographic inks. Measuring the physical properties of inks and understanding how these are affected by the choice of ingredients is a large part of ink technology. Formulation of inks requires a detailed knowledge of the physical and chemical properties of the raw materials composing the inks, and how these ingredients affect or react with each other as well as with the environment. Flexographic printing inks are primarily formulated to remain compatible with the wide variety of substrates used in the process. Each formulation component individually fulfills a special function and the proportion and composition will vary according to the substrate.

Flexography

'Flexography' (often abbreviated to flexo) is a form of printing process which utilizes a flexible relief plate. It is basically an updated version of letterpress that can be used for printing on almost any type of substrate including plastic, metallic films, cellophane, and paper. It is widely used for printing on the non-porous substrates required for various types of food packaging (it is also well suited for printing large areas of solid color.

Lithography

Lithography is a method for printing using a stone or a metal plate with a completely smooth surface. Lithography uses oil or fat and gum arabic to divide the smooth surface into hydrophobic regions which accept the ink, and hydrophilic regions which reject it and thus become the background. By contrast, in intaglio printing a plate is engraved, etched or stippled to make cavities to contain the printing ink, and in woodblock printing and letterpress ink is applied to the raised surfaces of letters or images.
Invented by Bavarian author Alois Senefelder in 1796, lithography can be used to print text or artwork onto paper or another suitable material. Most books, indeed all types of high-volume text, are now printed using offset lithography, the most common form of printing production. The word "lithography" also refers to photolithography, a microfabrication technique used to make integrated circuits and microelectromechanical systems, although those techniques have more in common with etching than with lithography.

Advantages of offset printing

Advantages of offset printing compared to other printing methods include:
• Consistent high image quality. Offset printing produces sharp and clean images and type more easily than letterpress printing because the rubber blanket conforms to the texture of the printing surface.
• Quick and easy production of printing plates.
• Longer printing plate life than on direct litho presses because there is no direct contact between the plate and the printing surface. Properly developed plates running in conjunction with optimized inks and fountain solution may exceed run lengths of a million impressions.
• Cost. Offset printing is the cheapest method to produce high quality printing in commercial printing quantities.

Disadvantages of offset printing compared to other printing methods include:
• Slightly inferior image quality compared to rotogravure or photogravure printing.
• Propensity for anodized aluminum printing plates to become sensitive (due to chemical oxidation) and print in non-image/background areas when developed plates are not cared for properly.
• Time and cost associated with producing plates and printing press setup. As a result, very small quantity printing jobs are now moving to digital offset machines.

Offset printing

Offset printing is a commonly used printing technique where the inked image is transferred (or "offset") from a plate to a rubber blanket, then to the printing surface. When used in combination with the lithographic process, which is based on the repulsion of oil and water, the offset technique employs a flat (planographic) image carrier on which the image to be printed obtains ink from ink rollers, while the non-printing area attracts a water-based film (called "fountain solution"), keeping the non-printing areas ink-free.

Color Printing

Color printing is the reproduction of an image or text in color (as opposed to simpler black and white or monochrome printing). Any natural scene or color photograph can be optically and physiologically dissected into three Primary Colors, red, green and blue, roughly equal amounts of which give rise to the perception of white, and different proportions of which give rise to the visual sensations of all other colors. The additive combination of any two primary colors in roughly equal proportion gives rise to the perception of a Secondary Color. For example, red and green yields yellow, red and blue yields magenta (a purple hue), and green and blue yield cyan (a turquoise hue). Only yellow is counter-intuitive. Yellow, cyan and magenta are merely the "basic" secondary colors: unequal mixtures of the primaries give rise to perception of many other colors all of which may be considered "tertiary."

While there are many techniques for reproducing images in color, specific graphic processes and industrial equipment are used for mass reproduction of color images on paper. In this sense, "color printing" involves reproduction techniques suited for printing presses capable of thousands or millions of impressions for publishing newspapers and magazines, brochures, cards, posters and similar mass-market items. In this type of industrial or commercial printing, the technique used to print full-color images, such as color photographs, is referred to as four-color-process or merely process printing. Four inks are used: three secondary colors plus black. These ink colors are cyan, magenta and yellow; abbreviated as CMYK. Cyan can be thought of as minus-red, magenta as minus-green, and yellow as minus-blue. These inks are semi-transparent or translucent. Where two such inks overlap on the paper due to sequential printing impressions, a primary color is perceived. For example, yellow (minus-blue) overprinted by magenta (minus green) yields red. Where all three inks may overlap, almost all incident light is absorbed or subtracted, yielding near black. It is because of this poor "subtractive" black that a separate black ink is used. The secondary or subtractive colors cyan, magenta and yellow may be considered "primary" by printers and watercolorists (whose basic inks and paints are transparent).
Two graphic techniques are required to prepare images for four-color printing. In the "pre-press" stage, original images are translated into forms that can be used on a printing press, through "color separation," and "screening" or "halftoning." These steps make possible the creation of printing plates that can transfer color impressions to paper on printing presses based on the principles of lithography.

Printing

Printing is a process for reproducing text and image, typically with ink on paper using a printing press. It is often carried out as a large-scale industrial process, and is an essential part of publishing and transaction printing.

Woodblock printing is a technique for printing text, images or patterns that was used widely throughout East Asia. It originated in China in antiquity as a method of printing on textiles and later on paper

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