2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16
Embossing is a manufacturing process of post-printing finishing, applying images to printed or souvenir products using foil or without it, under pressure and high temperature.
Relief stamping
Embossing is used for making postcards, business cards, labels and other souvenirs. Embossing with foil looks the most impressive, the finished material has a presentable and colorful look.
Types of embossing:
- blind (blind) embossing - extrusion of the print below the surface of the material used without the use of foil;
- embossing - compressing material between a special cliché, matrix and male to give the image a convexity; can be blind or foiled;
- hot foil stamping is a process of thermal transfer of metallized powder from a film onto an embossed material by means of a cliché. Various types of foil are used - metallized, textured, pigmented, holographic, etc.
Embossing is widely used for finishing diary covers, as well as business card holders, purses and other products made of artificial and natural leather.
Clichefor embossing there are photopolymer and metal (zinc, magnesium, copper, brass, sometimes steel):
- photopolymer cliches are used for small runs (up to 1000 prints) - business cards and souvenirs. This is the most economical option;
- zinc plates are used in the manufacture of products up to 10,000 prints;
- magnesium clichés have their own advantages: the ability to print on any material, fast production, runtime (up to 50,000 prints). Has an impression depth of 0.7-2.5 mm (depending on the material);
- brass cliches are made on special engraving machines by machining. Advantages - the possibility of giving the cliche several levels of depth, giving the embossing elements a greater height. They are used on soft materials with multi-level embossing. Runtime depends on plate thickness (more than 50,000 prints).
Photopolymer plates are a photopolymer deposited on a metal substrate and protected by a film from light exposure.
Metal plates are made in two ways - etching (chemical) and milling (mechanical). Relief stamping and other types of hot stamping are mainly performed by chemically produced clichés.
Stamping foil has the following composition:
1) lavsan base;
2) a thermally degradable wax-resin layer that breaks down when heated, releasing the lower foil layers;
3) paint layer (lacquer or paint layer) with binder;
4)a thin layer of aluminum, present only on holographic and metallized foils;
5) adhesive layer designed to bond layers to the material.
Heated to the required temperature, the cliche frees the colorful layers from the lavsan base and sticks them to the embossing material. The heating temperature is selected depending on the type of foil, type of cliché, embossed material, print pattern, equipment used and many other factors.
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