IPM February 2024

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Precise UV Curing ...........................................pg. 12 industrialprintmagazine.com

Elastomer Options for 3D Printing .................. pg. 14 UV Printing for Corrugated..............................pg. 24

#7

FEATURES [ 16] Beyond Basic Barware Direct to Glassware [ 24] Get Ready to Embrace UV for Corrugated

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Editor's Letter [Continuing Coverage] ........................................................... 4

Best Practices [Precise and Predictable]................................................... 12

News Beat [Current Industry News] ............................................................ 5

AM [A Look at Elastomers] ........................................................................... 14

AM [The Dark Side of AM] .............................................................................. 7

Advertiser Index/Companies Mentioned ............................................ 22

Spotlight [Forefront of Parts Production] ................................................... 10

Target Chart [Ease of Use for the Corrugated Market] ............................. 23

ON THE COVER LSINC PeriOne technology provides ease of entry into the direct to object market See page 16. industrialprtntmagazine.com

February 2024 [Industrial Print Magazine J 3

.RIAL 9PRINT

IN DUSTRIALPRI NTMAGAZI NE.COM Volume 11, Number 1

EDrTIIR'S LETTER

CONTINUING COVERAGE Welcome to 2024! While most of the conversation is on what's "new; this issue focuses on time-honored topics like printing directly to bar­ ware and UV and UV LED printing opportunities for corrugated board.

It's always beneficial to be aware of the next best thing, but keeping in-the-know on existing topics is just as advantageous.

One example, wineries, breweries, and distilleries are well poised to benefit from the technology afforded by today's UV direct to object printers. Our cover story, Beyond Basic Barware, discusses how print

area, ink adhesion, and durability continue to evolve to ensure high­ quality, directly printed decorations that stand the test of time.

Another continually discussed topic is corrugated, specifically as de­ mand for printed corrugated product is at all-time high. Inkjet printing, in particular UV/UV LED ink sets and how they are cured, is an ideal

decoration method. Read more in Get Ready to Embrace. The article is complemented by a chart that lists digital corrugated printers using various ink sets.

EDITOR IN CHIEF Thomas Tetreault 978-921-7850 EDITOR Melissa Donovan mdonovan@rockportpubs.com ASSOCIATE EDITOR Cassandra Balentine cbalentine@rockportpubs.com ART DIRECTOR Sarah M. White swhite@rockportpubs.com WEB EDITOR Melissa Mueller CONTRIBUTORS Pete Basiliere, Olivia Cahoon, Kemal Carr, Maria Conrado, Mark Hanley, Melinda Tetreault ADVERTISING SALES PUBLISHER Thomas Tetreault 100 Cummings Center, STE 321 E Beverly, Massachusetts 01915 Ph 978-921-7850 x110 • Fx 978-921-7870 edit@rockportpubs.com SALES Amanda Doyon Ph 978-921-7850 x170 • Fx 978-921-7870 adoyon@rockportpubs.com

The remainder of the issue includes three-dimensional printing con­ tent such as the development of elastomers, post-processing solu­ tions, and a spotlight on a recent customer of Solukon GmbH.

ROCKPORT

CusToM PuBLISHING

Happy New Year,

��2� Melissa Donovan, Editor

CORPORATE & PUBLISHING OFFICE 100 Cummings Center, STE 321 E Beverly, Massachusetts 01915 ROCKPORT CUSTOM PUBLISHING, LLC CHAIRMAN Jeffrey Jensen PRESIDENT & CEO Thomas Tetreault CONTROLLER Missy Tyler Industrial Print magazine is published by Rockport Custom Publishing, LLC. Please send change of address forms to: 100 Cummings Center, STE 321E, Beverly, MA 01915. © Rockport Custom Publishing, LLC 2024. Reproduction by any means of the whole or part of Industrial Print magazine without written permission from the publisher is prohibited. Views expressed in the editorial pages do not imply our endorsement.

Subscription Rates: U.S. $41.65 per year, seven issues; single copies: $5.95, Cana­ da and Mexico: $52.22 (U.S.D.), Other international subscriptions: $71.05 (U.S.D.) Vendors: We welcome your product news. Include prices, slides, photos, and digital files with your press release. Please forward product samples and media kits to Reviews Editor, Industrial Print magazine 100 Cummings Center, STE. 321E Beverly, MA 01915. We cannot be responsible for unsolicited product samples.

4 [lndustfia/ Print Magazine] February 2024

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INDUSTRY

CORETECHNOLOGIE UPGRADES 3D PRINTING SOFTWARE

CoreTechnologie upgrades the latest version of its three-dimensional (3D) printing software 4D_Additive with a new lattice structure module.

The new functions are used to create individual­ ized structures that enable a customized produc­ tion of lightweight mechanical components and consumer goods. For example, shoes and bicycle saddles can be customized to meet individual customer requirements.

Thanks to the software's new lattice structure functions, additively manufactured components with additional properties such as progressive damping, highly efficient heat exchange, light­ weight design, or functions of an assembly in­ tegrated into a single component can be quickly developed and optimized. The cell size and grid thickness of the structures can be adapted to the load profile using a color graphic so that the ar­ eas with higher loads are adaptively generated with a denser structure. The software's Nastran interface enables the seamless transfer of data to CAE calculation systems to validate the geom­ etries generated in seconds.

The simple creation of perforation patterns is possible with the help of new Boolean functions.

Thousands of holes of any size are automati­ cally generated so that they are perpendicular to the surface of the CAD model. Interesting ap­ plications for the 3D printing lattice technology include, for example, additively manufactured molds for vacuum thermoforming or the produc­ tion of catalytic converters. �INFD#171

industrialprtntmagazine.com

TRUMPF INCREASES PRODUCTIVITY OF TRUPRINT 2000

TRUMPF increases the productivity of its TruPrint 2000 three-dimensional (3D) printer. The TruPrint 2000 now comes with a square build plate and the power of a 500 watt integrated fiber laser offered as an alternative to the 300 watt laser in the basic configuration. As a multi­ laser version, the TruPrint 2000 has two lasers. Both la­ sers can process the entire build plate simultaneously, resulting in optimized throughput for production.

The TruPrint 2000 is especially fiexible due to variable spot size. With its motorized beam expander, the TruPrint 2000 automatically adjusts the spot diameter of the laser to the task at hand. Depending on the application, the spot diameter is 55 or 80 micrometers. The 80 micrometer spot enables higher productivity. Users can use the 55 micron spot when special metal powders require a higher energy density. The introduction of the 80 micron spot size brings the TruPrint 2000 in line with the rest of the machines in the TruPrint portfolio.� NF #170

FORMLABS ADDS RESIN PUMPING SYSTEM AND NEW MATERIALS

Formlabs announces a Resin Pumping System and two materials, Polypropylene Powder and Premium Teeth Resin. Formlabs' ecosystem is re­ lied upon for prototyping and in-house production and the Resin Pumping System as well as these new materials aim to bolster in-house printing for consumer goods, dental appliances, industrial and automotive parts, and manufacturing prototypes.

An accessory for the Form 3 and Form 3L printers, the Resin Pumping System is a plug-and­ play replacement for standard one liter cartridges that delivers five liters of resin directly to the printer's resin tank for continuous printing for five times longer.

NFD#172

U\lVI

EXCELITAS ACQUIRES HERAEUS

Excelitas Technologies Corp. announces the ac­ quisition of the Noblelight business from Heraeus Group, including operations in China, Germany, Japan, the U.K, and the U.S., along with key appli­ cation centers and sales offices around the world.

Noblelight specializes in specialty lighting components and systems, from UV to IR, used within analytical instrumentation, industrial curing, water treatment, electronics manufac­ turing, medical/cosmetic therapy, and battery production. Qli� NFD#173 1. CoreTechnologie upgrades the latest version of its 3D printing software 4D_Additive with a new lattice structure module. 2. Parts printed with recently introduced Polypro­ pylene Powder from Formlabs.

February 2024 {Industrial Print Magazine J 5

3DEO SECURES INVESTMENT

SPOTLIGHT WE ASKED TOP MANUFACTURERS TO SHARE THEIR LATEST PRODUCTS Parametric 3D Modeling App

Increased Production Capacity

WASP App is a new slicing and parametric 3D modeling application (app) for clay 3D printing that lets you create your own design objects by manipulating a series of parameters, such as shape, size, texture, and slicing settings.

The Mutoh XpertJet 1462UF UV LED flatbed printer is designed to elevate print productivity and deliver exceptional quality, making it the perfect fit for businesses seeking to expand their capabilities.

Users are able to export their gcodes and print them right away using WASP’s Clay 3D printers, even in series, printing multiple pieces one after the other. Visit app.3dwasp.com for more information.

INFO# 178

Featuring a table size of 55x27 inches, the XpertJet 1462UF stands out. This large dimension allows for increased production capacity and profitability, enabling users to print on objects up to 5.91 inches thick. It can achieve multi-layer printing at speeds of up to 41.8 square feet per hour. For more information visit mutoh.com. INFO# 179

3DEO announces a significant investment from the Development Bank of Japan Inc. and Seiko Epson Corporation. This partnership marks a pivotal step in 3DEO’s expansion and underscores the confidence in its proprietary end-to-end threedimensional (3D) printing technology.

3DEO’s approach focuses on a specialization in complex metal 3D printed components/ assemblies and advanced Design for Additive Manufacturing (DfAM), and is underpinned by a differentiated portfolio of 18 patents. 3DEO’s purpose-driven vision empowers customers to innovate and design competitively positioned products, while its end-to-end solution, encompassing proprietary software, metal 3D printers, robotics, and materials, streamlines the production process. This integration reduces the complexity for clients, allowing them to scale up without the burden of mastering additive manufacturing processes themselves, supported by 3DEO’s DfAM training and expertise.

The investment will propel 3DEO’s growth strategies in North America and Japan, expanding opportunities for partnership in the semiconductor, aerospace, medical devices and equip#176 ment, and industrial sectors.

DCS ANNOUNCES VIBRAHUE PRINTERS

FUJIFILM LAUNCHES THE 46KUV INKJET PRINTBAR SYSTEM FUJIFILM Integrated Inkjet Solutions launches its FUJIFILM 46kUV Inkjet Printbar System, a new integrated print solution for industrial production operations for printing on a range of labels and packaging material. The FUJIFILM 46kUV Inkjet Printbar System features a drop on demand design to streamline workflow with fast, industry-leading printing speeds of up to 500 feet per minute.

Fujifilm’s 46kUV Inkjet Printbar System uses Fujifilm’s proprietary SAMBA printhead technology, which leverages the precision of silicon MEMS processing and sputtered PZT in an ingenious parallelogram shape. Additionally, Fujifilm’s 46kUV Inkjet Printer System has a native resolution of 1,200 dots per inch to cover a range of today’s label quality needs, and can print individually unique quick response codes, as well as produce highquality small fonts.

6 [ Industrial Print Magazine ] February 2024

Fujifilm’s 46kUV Inkjet Printbar System is available in four print widths, including 10, 13, 17, and 20 inches to integrate seamlessly into traditional printing processes, minimizing the need for extensive training and process changes. Fujifilm’s 3IC document creation software is used with the 46kUV Inkjet Printbar System to efficiently create variable data content. The printbar’s cleaning and capping module is designed to help maintain image quality. The 46kUV Inkjet Printbar System utilizes Fujifilm’s proprietary REDIJET patented ink recirculation to optimize image quality across the print width to minimize the need for printhead re#174 furbishment.

XJET COLLABORATES WITH XOLUTIONS XJet announces a collaboration with XOLUTIONS, the latter acquiring the XJet Carmel 1400M printer to propel research and development on the application of this technology within the fashion and #175 luxury sector, comprising jewlery.

Direct Color Systems (DCS) introduces a new line of printers to its current portfolio. The product line, named VIBRAHUE, is a collaboration between DCS and Team EPS. DCS, well known for its innovative products for braille and textured printing, is adding the VIBRAHUE product line to meet the needs of traditional UV printing. Team EPS is a 30 year old service company to the printing industry and is very well known for providing exceptional technical service and support.

The VIBRAHUE line is a fast, reliable, and competitively priced portfolio of printers with flatbed, roll to roll, and hybrid formats. They are available in a variety of sizes and a choice of printheads. DCS handles the sales and marketing for the product line, while Team EPS manages the installation, training, technical support, and service. This is part of DCS’ broader vision to strengthen its market presence while bringing new product possibilities to its existing customer #177 base.

industrialprintmagazine.com

AM

THE DARK SIDE OF AM Post-Processing Disruptions

by Melissa Donovan

Post-processing three-dimensional (3D) printed parts involve many processes, which depend on the material and print technology used. Multiple vendors provide hardware just for this purpose. However, 3D printer manufacturers are dipping their toes into post-processing to offer a full 3D printing ecosystem.

For example, Formlabs—manufacturer of selective laser sintering (SLS) and stereolithography (SLA) printers—announced at Formnext 2023 the Fuse Blast. The fully automated part cleaning and polishing solution is billed as part of the Formlabs printing ecosystem. Formlabs’ line includes post-processing tools for both SLS and SLA 3D printing with the Fuse Sift, Fuse Blast, Form Wash, and Form Cure, enabling users to easily finish any Formlabs part with high-quality results.

1 Alternatively, OEM printer manufacturers also sanction collaborations with post-processing manufac- technology. It modified its standard metal injection molding turers after undergoing significant evaluations to ensure their debind and sinter furnace to accommodate the requirements printers work well with third-party vendors. demanded by the HP technology.

DyeMansion Inc. and Nexa3D recently announced plans to Benefits of Same Manufacturers strategically partner and automate end-to-end AM workflows— from printing to finished parts. The partnership leverages It’s nice to have options, whether it’s committing to a full-scale DyeMansion’s automated post-processing hardware, the high- ecosystem or third-party partners.

When working with post-processing and 3D printing devicthroughput capabilities of Nexa3D’s QLS 820 printer, as well es from the same manufacturer, users benefit from “improved as the printer’s Siemens PLC integration and powerful NexaX simplicity, consistency, and ease of use at each step in the profor QLS manufacturing software. cess—enabling simple HP Inc. and Elnik planning, printing, and Systems is another post processing,” exexample. Elnik, a vetplains Matt Ewertowseran in the debind and ki, hardware product sinter furnace indusmanager, Formlabs. try, collaborated with “Throughout the the HP team to help — Andreas Hartmann, CEO/CTO, Solukon 3D printing process, drive adoption of metal a complete solution additive part making

The challenges in post-processing just like in the printing process itself are constantly rising.

industrialprintmagazine.com

February 2024 [ Industrial Print Magazine ] 7

•

specialty-depowdering-to post-process complex parts requires a "software that calculates the ideal motion sequence to get the powder of all cavities." Solukon launched this in a joint project with Sie­ mens in 2018 and continues to develop it on a constant basis.

"From my point of view, specialized post-processing companies are the way to go. This way post-processing matters get the attention they need without over­ looking the printer manufacturers' per­ spective and know-how of the produc­ tion process. We at Solukon have strong partnerships with OEMs like AMCM, DMG MORI, EOS, Nikon SLM Solu­ tions, and Velo3D," explains Hartmann.

from the same manufacturer provides continuity across the ecosystem, includ­ ing software integrations, whole system support with compatibility across devic­ es, and a smooth, consistent user expe­ rience, from purchase to onboarding, to post-sale support. These improved work­ flows can also unlock new opportunities for automation, yielding consistent and reliable results with reduced labor cost," continues Ewertowski.

Andreas Hartmann, CEO/CTO, So­ lukon GmbH, agrees that "from a user's point of view it might generally be ben­ eficial to work with as few manufactur­ ers as possible for printing and post-pro­ cessing. But reality shows that, at least in the laser powder bed fusion process,

COM PAN IES MENTION ED INFO# Company 146

AMCM, an EOS company

148

DyeMansion Inc.

147 149

150

151

not one provider can cover all process steps-i.e. printing and all post-process­ ing steps."

There are two main reasons for this, according to Hartmann. First, he men­ tions that post-processing equipment is considered "the dark side of AM," meaning that it is somehow an unpleas­ ant job compared to working on the parameters for the print job. "This per­ spective is obviously wrong since qual­ ity of post-processing directly affects part quality and performance."

The second reason, "post-processing is quite challenging and it needs special focus to offer the best possible solution for the market," continues Hartmann.

Providing the example of Solukon's

·p�seepage22for moreinformation.

Website

amcm.com

DMG MORI

us.dmqmori.com

Elnik Svstems

elnik.com

Formlabs

formlabs.com

EDS

dyemansion.com

eos.info/en

152

HP Inc.

154

Nikon SLM Solutions

slm-solutions.com

Solukon GmbH

solukon.de

153 155 156

157

Nexa3D

Siemens

Velo3D

8 [lndustfia/ Print Magazine] February 2024

hp.com

nexa3d.com

siemens.com

velo3d.com

Third-Party Perks As Hartmann alluded to prior, there are advantages to working with a third-party provider that's endorsed by a 3D print­ ing manufacturer.

Primarily, "the post-processing part­ ner of choice has in-depth knowledge in their business field, from which the user benefits," explains Hartmann.

Another advantage, the openness between post-processing device and printer. ''A large amount of customers rely on printing systems from different manufacturers. Working with an inde­ pendent, third-party post-processing company guarantees an openness that the post-processing equipment is com­ patible with printers of all brands," shares Hartmann.

There are specific scenarios where a third-party option makes more sense.

"One case where you are better served going outside the printer ecosystem is 1. With pre-programmed settings for specific materi­ als, tools to reclaim unused materials, and automated cleaning and finishing tools, Formlabs offers a fully complete ecosystem of post-processing devices that are designed to work seamlessly with Formlabs' suite of printers, enabling users to have a unified workfiow from ideation to finalized prints. 2. Solukon's depow­ dering systems are approved for safe and reliable processing of powder materials, including tough-to­ handle and reactive metal powders.

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if your requirements or end-use applications are particularly niche and just aren’t compatible with the available configurations. Ecosystem manufacturers prioritize solutions that deliver the most value across their entire user base, and with so many potential post-processing options they must aggressively choose where to allocate resources, so some post-processing techniques or configurations just don’t make the cut. In these cases, going with a vendor that has built a solution for that specific need may be the only option,” notes Ewertowski.

Of course, there is also the argument about the disadvantages or risks. These include “relying on a separate company to support and service your equipment, with no guarantees on compatibility with your particular 3D printing process or application. Software solutions are

not guaranteed to maintain compatibility in future updates, which means you may have to change your process later.

If the third-party vendor chooses to stop supporting the product, you’ll also have to take on additional maintenance burdens,” advises Ewertowski.

The Future?

It’s a slippery slope when discussing the future of additive manufacturing (AM). There are many different postprocessing techniques out there, so it’s hard to say if post-processing and 3D printing devices from the same manufacturer are the way of the future.

“The challenges in post-processing just like in the printing process itself are constantly rising. So do the manufacturing methods and the number and variety of materials. Especially in these politically and economically challenging times, it

#4

is better to place hope on several players instead of one,” stresses Hartmann.

Ewertowski admits that many 3D printer manufacturers do not offer complete ecosystems, however, “a thoughtful, end-to-end solution is the best way to ensure that users will receive a consistent and reliable experience, which ultimately leads to faster ramp up, higher printer utilization, and a better overall 3D printing experience. Formlabs is ahead of the curve in that respect, having already delivered a complete ecosystem that helps you go from design to finished part.”

Whatever the future holds, it’s an exciting time for 3D printing. If anything, the introduction of ecosystems like that from Formlabs shines a greater spotlight on just how instrumental postprocessing is in the AM workflow to achieve a finished part. IPM

SPOTLIGHT

FOREFRONT OF PARTS PRODUCTION Post-Processing Systems

by Industrial Print Magazine Staff

Systems that offer automated post processing of a three-di­ mensional (3D) printed part are integral to the technology mov­ ing and excelling past prototyp­ ing and into full serial produc­ tion. As more manufacturers consider and ultimately adopt additive manufacturing (AM), a post-processing solution is in­ creasingly part of the equation.

German Automobiles Solukon Maschinenbau GmbH is a well-known supplier of post­ processing systems, specifically powder removal and processing solutions for metal and polymer AM. In November 2023, the company announced that auto­ mobile manufacturer, The BMW Group, integrated a post-pro­ cessing system from its portfolio into its Additive Manufacturing Campus located in Oberschleissheim, Germany. and blasting unit for surface cleaning and finishing with ionJust outside of Munich, the facility opened in 2020. It ized compressed air for selective laser sintering parts. houses nearly 50 industrial systems for processing metal and plastics. The community combines production of prototype Four-Step Process and series parts, conducts research into 3D printing technol- Using the SFP770, the cleaning process occurs in four main steps. The first, loading, ogies, and offers asso­ - - - - - ,,- - - - - - ciate training on tool­ where the build box of less manufacturing. the 3D printer is placed BMW plans to use in the system by a lift the Solukon SFP770 truck. Second, unpack­ to unpack and clean ing. Here, a vibrating prototype parts made sieve cover is placed of polyamide. It con­ - Andreas Hartmann, CE0/CT0, Solukon sists of a combined 1. Cross section view of the Solukon SFP770. automated unpacking ,,

Another advantage of our system-parts of different shapes and sizes can be cleaned at the same time.

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industrialprintmagazine.com

over the inserted build box, which then rotates gently overhead following an optional programmable process, gradually unpacking the components. The loose powder is extracted from the sieve cover directly and without contamination, and then conveyed to a recycling unit.

During the third step, transferring, the build box rotates towards a basket and opens the sieve cover. The sieve cover now functions as a slide and the parts are slipped carefully into the basket. If necessary, the automatic transfer process can be paused to manually remove certain components that should not be cleaned automatically.

The fourth part of the process is when the cleaning occurs. The basket rotates in the direction of the blasting unit and begins turning. The fully automated cleaning process consists of glass bead blasts and ionized air, which removes residual powder. Users easily program online process parameters such as rotation angle, blast intensity, distance, and basket rotation.

SFP770 is an ideal cleaning and unpacking station. It unpacks and cleans a fully loaded build box with an assembly space of 150 liters in only 30 minutes, which is why it can handle several jobs per day,” adds Hartmann.

Post-Processing Needs To meet high levels of production, BMW chose to implement the Solukon SFP770. AM is more than just the printer, it requires an efficient post-processing solution as well. IPM

Advantages of the SFP770 BMW uses the SFP770 to clean plastic parts, specifically polyamide. There are a few reasons the technology was integrated and validated into its production line.

“Because so many process parameters can be programmed, the SFP770 achieves the best cleaning results, regardless of the part material and without any manual intermediate steps. Another advantage of our system—parts of different shapes and sizes can be cleaned at the same time,” explains Andreas Hartmann, CEO/CTO, Solukon.

Both of these benefits significantly increase the level of flexibility in prototype post processing. “Especially for companies with a high part output. The

C O M PA N I E S M E N T I O N E D See page 22 for more information.

INFO# Company 106

Website

Solukon Maschinenbau GmbH solukon.de #5

industrialprintmagazine.com

February 2024 [ Industrial Print Magazine ] 11

BEST PRACTICES

PRECISE AND PREDICTABLE Making a Point

by Industrial Print Magazine Staff

Precise UV curing in industrial print applications is essential. The exact measurement of energy must be met each time to ensure that ink adhesion and any other specifications are achieved.

“Most UV inks require a specific energy density or dose to reach the advertised specifications—adhesion, scratch resistance, hardness.

Light sources that either under or over cure can cause waste in the form of scrap prints that cannot be used,” explains Stacy Hoge, Phoseon, marketing manager, Excelitas Technologies Corp.

Errol Moebius, president/CEO, IST America, believes “the necessity for precise curing arises from the stringent demands of the coating, ink, or adhesive, which often require an extremely specific curing timeframe. This demands a stable and tightly controlled output, often monitored through closed loop systems.”

How to achieve a tightly monitored system depends on the user and application(s) printed, but in any scenario, they benefit from precise UV curing.

The Importance of Precision

1 In such applications, curing is often a crucial step in constructing components holding together critical parts of vehicles or aircraft. Without precise curing, there’s a risk of compromising safety and quality, potentially leading to concerns regarding the integrity of these critical components,” shares Moebius.

“If an area of a print is over cured, the ink can crack and flake. If it is under cured, it will remain tacky and possibly smear. Over and under cured materials can

Users expect predictable output, especially in today’s fastpaced world. Industrial digital print applications are no exception.

Industrial, automotive, and aircraft manufacturing industries are just some of the segments that require precise curing. “It is essential due to the need to — Errol Moebius, president/CEO, IST America access challenging areas or specialty shapes.

Without precise curing, there’s a risk of compromising safety and quality, potentially leading to concerns regarding the integrity of these critical components.

12 [ Industrial Print Magazine ] February 2024

1. IST America offers a

range of UV curing solutions.

industrialprintmagazine.com

BEST PRACTICES.

result in unusable printed material and excess scrap. These results can also lead to increased downtime for the printer," notes Hoge.

This is why Excelitas' line of Phos­ eon products feature TargetCure Tech­ nology. It offers stable curing over the lifetime of the unit, consistent through temperature variation, and precise cur­ ing when the lamp is turned on.

Precise curing when a lamp is turned on is especially helpful. "When air­ cooled products are first turned on, they overshoot the target irradiance resulting in over cured and brittle material. Tar­ getCure Technology delivers precise ir­ radiance, eliminating overshoot and pro­ viding a consistent and reliable cure," explains Hoge.

How to Achieve Precision UV curing providers offer proprietary technology to achieve precise curing.

For example, Excelitas' Phoseon UV LED curing products use proprietary technology to maintain stable output, both over the life of the lamp and during each run. This keeps the product of the print job consistent from start to finish, with no over curing at the beginning.

"Phoseon's patented Semiconductor Light Matrix technology encapsulates LEDs, arrays, optics, and cooling to maximize UV LED curing performance and precise curing. Each of these four components are strictly engineered into a system that provides maximum UV energy and superior performance while also increasing long-term robustness for demanding applications," shares Hoge.

2. Excelitas' Phoseon FireEdge and FireJet prod­ ucts are air cooled, compact UV LED curing lamps ideal for large and small area curing for digital inkjet printing.

COMPANIES MENTIONED INFO# Company 164 165 166

America IST accomplishes pre­ cise curing through a combination of technologies re­ fined over 25 years, according to Moe­ bius. "Our system utilizes a high-pre­ cision radiometer beneath each UV bulb, allowing us to control irradiance levels precisely and to a set value that can then be auto­ matically controlled. Additionally, our engineered reflectors manage 75 per­ cent of the bulb's output by reflecting short-wavelength UV and allowing long­ wavelength infrared to pass through.

Moreover, our solid-state power con­ trollers enable fine adjustments to the lamp's power output."

UV Curing Products The following vendors promote UV cur­ ing systems with precise curing.

Phoseon UV LED curing products from Excelitas are ideal for digital print­ ing applications due to the compact size, ease of integration, and high inten­ sity output achieved through optimized thermal management of the LEDs. The FireEdge and FireJet products are air cooled, compact UV LED curing lamps ideal for large and small area curing for digital inkjet printing. The FireEdge prod­ ucts are also well matched for pinning to "freeze" the ink without fully curing.

Phoseon FireLine products are wa­ ter-cooled UV LED curing lamps with uses in a variety of web/conveyor-based, UV curing applications. The FireLine

Pfl ir I See page 22 for more information.

Website

Excelitas Technoloqies Corp.

excelitas.com

ProPhotonix Limited

prophotonix.com

1ST America

industrialprtntmagazine.com

ist-uv.com/en-us

architecture is designed to allow the systems to be scalable and built up to two meters in length.

IST America offers a range of UV curing solutions. Some competitors opt for a more standardized "plug-and-play" method, but IST's approach involves close collaboration between its techni­ cal experts and clients. IST works to understand each clients' unique chal­ lenges, specifications, and ultimate objectives. This understanding allows for tailor-make solutions that precisely meet those individual needs.

ProPhotonix Limited offers indus­ trial laser modules placed in UV cur­ ing systems, this includes UV lasers at 375nm. In UV curing applications, 375nm lasers can provide precise cur­ ing of small areas. This precision cur­ ing is ideal when areas or components around the target area are susceptible to damage from UV radiation. UV laser diode modules can enable higher speed and higher definition in three-dimen­ sional printing applications.

It's In the Details Precise curing plays an important role in the overall printing process. Without it, ink can crack or smear; compromis­ ing the integrity of a part or print. With correct systems in place these errors are avoided. 1PM

February 2024 {Industrial Print Magazine J 13

AM

A LOOK AT ELASTOMERS Advancements Continue

by Cassandra Balentine

The three-dimensional (3D) print—particularly additive manufacturing (AM)—world relies on a variety of materials for product and part building. Elastomers are rubber-like polymers with elastic features, which are ideal for seals, adhesives, and flexible parts.

3D printing processes that print elastomers include stereolithography (SLA), fused deposition modeling (FDM), multi-jet fusion (MJF), and selective laser sintering (SLS). Each technology has some pros and cons, but Sam Houston, senior manager, Advanced Laser Materials (ALM) global, EOS, says it really depends on the end part and what is needed to choose the right one for the application.

According to Grand View Research, the global elastomers market size was valued at USD $82.41 billion in 2019 and is anticipated to grow at a compound annual growth rate (CAGR) of 4.8 percent from 2020 to 2025.

1 The firm’s Elastomers Market Size, Share & Trends Analysis Report By Application (Consumer Goods, Medical, Au- production. Key properties, such as high durability, strength, and tomotive, Industrial), By Type (Thermoplastics, Thermosets), By pliability, allow it an ideal material for a variety of applications Region, And Segment Forecasts, 2020 - 2025 report explains in the automotive sector,” says the Grand View Research report. that elastomers are elastic polymers that are lightly cross-linked Elastomer Features and amorphous along with glass transition temperature. They Several features are in demand when it comes to elastomers, are classified as thermoplastic, diene, and non-diene. Thermoplastic elastomers (TPEs) block copolymers contain rigid and including elongation at break, impact resistance, recyclabilsoft repeat units. Elastomeric parts are produced through three ity, consistency in processability, and post processing, accordmajor production techniques—injection molding, compression ing to Houston.

The most in demand functions of elastomers come down to molding, and transfer molding.

“Rising demand from key application areas coupled with the application. For example, those that utilize 3D printed, flexadvancements in the processing technologies is likely to propel ible elastomers often require many properties that aren’t traditionally associated with the market growth durtraditional 3D printed ing the forecast period. materials. Footwear apElastomers are witnessplications demand high ing high demand from the automotive industry 1. In close collaboration with on account of the rising the Carbon team, adidas need for high-perfor— Sam Houston, senior manager, ALM global, EOS leverages the Carbon DLS mance and lightweight process and EPU 41 3D printing material. materials in vehicle

The use of TPEs in AM can provide unique lattice structures for a futuristic look...

14 [ Industrial Print Magazine ] February 2024

industrialprintmagazine.com

AM

levels of durability and fatigue strength, fine features that won’t tear or rip when in use, cleanability, and a surface finish thats aesthetic has to be appealing, shares Jason Rolland, SVP of materials, Carbon, Inc. “TPEs are used for many different things but most of the time, clients are looking for a certain shore hardness, a method used to characterize how resistant materials are to localized deformation or indentation—more or less, how hard, or soft the material is,” says Houston.

Pareekshith Allu, materials manager, Formlabs, sees a need for materials that are able to print tear resistant and durable to produce intricate surface finishes that are skin-safe in low production times.

Additionally, the ability to mimic injection molded silicones and urethane rubbers with the right durometer are highly in demand. “Effective elastomers should be able to make parts that would be difficult to cast or die cut otherwise, and chemically inert parts with high temperature stability and rebound resilience. This enables users to make seals or gaskets on demand and in the right form and fit for product development or manufacturing,” says Allu.

Demand for the feature sets required of elastomers also come down to the application and end use of a part. However, it often needs to be able to withstand certain conditions such as resistance to fatigue, tears, water, UV, impact, and certain chemicals, as well as be cost competitive to the traditionally manufactured parts, says Houston.

“Demand for these features will always be driven by the end customer and the ultimate performance of the product. Saddles are a good example of having a material that gives designers and

C O M PA N I E S M E N T I O N E D INFO# Company

engineers new found capabilities in the design process to meet and exceed the demands of their performance-driven users. These capabilities include, but are not limited to, variable density in a single monolithic print, breathable/light weight structures, and new aesthetics and designs that delight the customer,” adds Rolland.

Allu points out the example of casting silicone parts, which is a multi-step and laborious process. “Users usually 3D print two mold halves and inject silicone into the molds to make silicone parts. There is a challenge with designing the molds and it can be an iterative process to get the final parts. This is a slow method compared to 3D printing for quick iterations and prototyping.”

Allu also shares that transfer molding for silicone requires making molds that are then used to inject silicone to make silicone parts. “Outsourcing to service bureaus can take several days to weeks for parts and is very expensive compared to in-house 3D printing.”

Elastomers in Industry Several industries rely on elastomers as part of their 3D production processes.

Many consumer industries benefit from the unique properties and design affordances of 3D printed elastomers.

“Really anywhere that the user needs next-level performance in the areas of comfort, breathability, protection, and novel aesthetics. One area where we’re excited to see growth is in the custom products world. We want to create the systems and workflows that enable mass customization at scale for any purpose. From bespoke fit for helmets across sports, to insoles, to wheelchair seating,” says Rolland.

See page 22 for more information.

Website

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Carbon, Inc.

carbon3d.com

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EOS

eos.info

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Formlabs

formlabs.com

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Houston feels the largest industries utilizing elastomers include lifestyle, automotive, aerospace, and industrial. “We have seen a rise in footwear. The use of TPEs in AM can provide unique lattice structures for a futuristic look as well as great rebound performance needed for the lifetime of the shoe. Many other verticals might use these materials to produce parts such as grippers, gaskets, seals, and latticed cushions.”

Allu also sees increased adoption of elastomers in 3D printing in healthcare, consumer goods, manufacturing, and engineering industries. “This is due to elastomers’ ability to bridge the gap between manufacturing stages, produce fully functional prototypes, manufacturing aids, and end use parts, as well as take full control of their supply chain.”

Within the aforementioned industries, specific applications utilize elastomers.

Allu points out that these applications include handles, grips, overmolds, seals, gaskets, masks, damping, shock absorption, rippers, padding, and cushions.

Biomed applications include cartilage, tendon, and ligament anatomy.

In the healthcare and dental industries, labs and clinics look for elastomeric materials that produce patient-specific parts and products, adds Allu.

Rolland says soft robotics is a developing field of technology utilizing Carbon’s elastomers to create soft grippers that can be embedded with electronics, creating a sense of touch. “We have customers using our products on assembly lines to create grips that grab various shaped products for sorting. Our damping materials, like EPU 45, are often used to stabilize sensitive electronics against noisy vibrations.”

Elastomers in Use We continue to watch the development of elastomers utilized in AM. These are increasingly popular in a range of industries, from consumer to healthcare. IPM

February 2024 [ Industrial Print Magazine ] 15

sometimes even combined with label for direct decoration at the front and label with more technical information at the back."

Growing Adoption Continued advancements in DtO print­ ing specific to glassware make it easy for print providers to offer a variety of custom barware to craft breweries, wineries, and distilleries.

"In my experience, the adoption of DtO printing within the glassware in­ dustry has been remarkable," claims Riley Mann, marketing specialist, Inkcups. "There's a discernible shift towards leveraging the unique capabil­ ities of digital UV DtO printing, particu­ larly for pint glasses, wine tumblers, and beer bottles."

This trend is driven by the versatil­ ity of digital printing, allowing for the replication of various print outcomes.

"Techniques such as mirror print, tone on tone, contour print, and others have gained popularity, making digital decora­ tion the preferred and effective method for achieving high quality and custom­ ized results in glassware," says Mann.

A notable example is the use of con­ tour print to elevate the perceived value of wine bottles. "This technique provides a textured three-dimensional feel to the design, creating a level of sophistication and uniqueness that sets the product apart," adds Mann.

"The adoption of direct print to glass­ ware is a natural extension of a large existing market that includes souvenir, commemorative, and branding that is

currently printed through other methods such as pad printing," shares Hugo Gon­ zalez, senior segment specialist, indus­ trial printing, Mimaki USA, Inc. For many years, glass has been printed on directly using different tech­ nologies. "Predominantly, pad and screen printing technologies were very successful. There is now a big push in digital printing on all types of glass. This is where we see the biggest opportunity because the technology and process has advanced to become as efficient if not more efficient than the other two pro­ cess that have been adopted," shares Jim Lambert, CCO, LSINC. Gonzalez explains that digital UV technology offers the ability to print full­ color, photorealistic, and smooth gradi­ ent images and logos with minimal setup

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1 and wasted resources. “This is particularly beneficial for customers seeking low-quantity batches of customized and personalized designs.”

Jay Larsen, GM/director of R&D, digital inkjet systems, INX Digital, feels that digital printing on glassware is well past the commercial acceptance stage.

ADOPTING AI Artificial intelligence (AI) is a topic trending across nearly all industries, including in the world of direct to printing (DtO) on glassware.

Riley Mann, marketing specialist, Inkcups, says AI is becoming increasingly integrated into advertising and packaging strategies among local breweries. “We have seen a local brewery jump on the AI train incredibly early on with tremendous success. The use of AI in these early stages is intriguing, and it will be fascinating to see if breweries, known for their innovative spirit, will fully harness AI’s potential for enhancing artwork on their barware.”

Further, the recent launch of Adobe AI plugins adds another layer of excitement to the future of DtO printing. “As this innovative tool gains traction, we anticipate a surge in experimentation with graphics and branding. The intersection of AI and DtO printing opens up new possibilities for elevating visual elements, and it will be intriguing to witness the creative transformations that result from this dynamic synergy,” shares Mann.

The evolving landscape of DtO printing holds immense potential for breweries and wineries, and the convergence of AI and printing technologies is poised to redefine the aesthetics of barware in exciting ways.

18 [ Industrial Print Magazine ] February 2024

“Printers are mostly suitable for shorter production runs with variable data or special digital embellishments. Many hundreds of printers are installed in the market, printing on glass and using our JetINX print engines.”

Tooling and software advancements continue to enhance the appeal for breweries/wineries and those print operations that supply them. “Items ranging from shots and whiskeys to pints and growlers can now be decorated. Combine all of that with the ability to process art files directly from the web and glassware continues to be one of the most popular applications for UV rotary printers,” says Michael Perrelli, marketing and sales director, Innovative Digital Systems.

The acceptance and adoption varies geographically. “I just returned from Europe and one of the biggest things I 1. Innovative Digital Systems’ entire UV rotary printer

line is capable of printing glassware in full color with proper adhesion.

industrialprintmagazine.com

see, especially in Germany, is breweries supplying the decorated glass to the bars and restaurants. These branded glasses are used exclusively for the beer supplied by the breweries,” shares Paul Bolduc, president, Koenig & Bauer Kammann (US) Inc. “In the U.S. we are still a long way from this.”

Direct Benefits Compared to traditional methods like screen and pad printing, DtO brings the capabilities of digital print to barware, including short runs and customization.

Digitally printing to glassware provides flexibility in small quantity orders, multicolor imprints, and greater customization capabilities. “Rotary digital printing allows you to conduct smaller quantity glass drinkware runs at less

cost, ultimately saving time and money,” stresses Perrelli.

“One of the biggest benefits is the available printable area versus that of an applied label,” says Lambert. Brand owners push this because it gives them more real estate to convey their marketing message on store shelves. “There are also possibilities with high build tactile effects that just aren’t possible with traditional conventional labeling. This is also an advantage over silkscreen and pad printing processes. Also noteworthy is the sustainable characteristics of the digital ink on glass specifically with regard to the recycling and reuse options that are available.”

Bolduc agrees, noting that with DtO, Koenig & Bauer Kammann equipment prints excellent quality glassware with

excellent durability, even on shaped glass articles. “We use a Xaar printhead, which has a 70 millimeter (mm) print area, so if the artwork is bigger than 70 mm in the longitudinal direction we would have to print in two or more passes. We have solutions for this too if needed.”

Digital UV technology also eliminates additional setup required between jobs/designs or job quantities.

“In popular methods such as pad printing, a printer would have to use the same amount of chemicals and ink to start the press if they were going to print two cups or 200 cups. Additionally, they would have to start up a printer for each additional color or clean the press to print the next color.

With digital UV/DtO technology, there

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February 2024 [ Industrial Print Magazine ] 19

The process is ideal for multi-color designs and industrial use. "Inkjet print­ ing is optimal for companies aiming to produce multi-color designs, especially in large-volume industrial applications, offering a versatile solution for glass decoration," offers Mann.

Working Past Limitations

is no setup or wasted ink or chemicals to change between designs, colors, or customers. This is why pad printing usually requires minimums in order to reduce the overall setup per piece cost.

The real benefit is the ability to print high-quality short runs, photorealistic images, and a significant reduction in setup and clean-up time. Similar ad­ vantages exist over screen printers," offers Gonzalez.

Mann says DtO printing offers quality. "Inkjet printing ensures that finished glassware products exhibit a

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high quality and uniform appearance, enhancing their overall aesthetic appeal."

It also offers cost-effective and quick results. "UV digital printing on glass stands out as a revolutionary and cost­ effective technology, providing quick and professional results at a lower cost per print," adds Mann.

DtO provides immediate readiness for shipping. "Unlike some other methods, there is no drying necessary in the ink­ jet printing process, allowing glassware products to be immediately ready for ship­ ping after production," continues Mann.

W�Seepage22for moreinformation.

Website

lnkcups

inkcups.com

INX Digital

inxinternational.com

Innovative Digital Systems Koenig & Bauer Kammann LSINC

Mimaki USA, Inc.

20 [lndustfia/ Print Magazine J February 2024

ids-digital.com

kammann.de/en lsinc.com

mimakusa.com

While there are many benefits to DtO printing for glassware, there are also limitations to consider.

Until recently these advanced pieces of machinery and corresponding tech­ nology have come with a substantial price tag, admits Mann. However, ac­ cessibility continues to improve. Mann points to the release of Inkcups' Helix ONE benchtop printer as an example of a more accessible DtO system.

When it comes to short runs and customizations Perrelli doesn't see limi­ tations outside of the decoration area on intricate shaped items. "Most of the glassware that comes through our Ap­ plications Lab can be digitally printed.

Our team analyzes the product and then tests for safe rotation-tooling, adhe­ sion, and ensuring the largest possible print area is achieved." ''A big challenge is awareness among designers and brand owners, so spreading the word about the benefits of direct decoration is important," rec­ ommends Maas.

Improving Printability As DtO print technology advances, it be­ comes easier to print to glass objects.

"Speed, adhesion processes, and tooling have advanced over the past couple of years to where operators can UV print glassware faster and better 2. LSINC PeriOne technology provides ease of entry into the 010 market while also providing fast, efficient, and productive performance for light production print­ ing to cylinders and tapered media. 3. Mimaki offers the UJF Series of bench and tabletop UV LED flatbed printers with the Kebab option, specifically for em­ bellishing cylindrical objects.

industrialprintmagazine.com

than ever before,” comments Perrelli.

Larsen shares that incremental improvements in surface treatment options, cleaning methods, and ink technologies were made over the past few years.

For example, INX offers patented helical print technology to allow the printheads to perform at full speed with resolutions higher than the native printhead resolution and nozzle redundancy. “This allows for continuous production of 3 quality products to meet the customer’s needs. In addition, we provide ink and treatment options for difficult substrates that allow for printing of durable finished products,” says Larsen.

Advancements in drives and controls have led to faster machines with higher throughput, points out Maas. “Hardware and software for inkjet print modules, such as INX’s JetINX technology, today allow for accurate ink drop deposition at a range of speeds, article geometries, and ink viscosities. Ink chemistry itself has improved in its performance in various areas, such as curing/drying properties, operability, and chemical components.”

Mann comments that the Transparent Pin Curing feature for Inkcups Helix machines allows operators to skip the time-consuming step of stuffing each clear vessel with a foxtail. “Traditionally, UV inkjet printing on clear vessels requires a stuffing agent known as a foxtail to block the UV light from curing the ink and damaging the printheads. With this technology, containers remain uncontaminated and sterile on the inside and printhead life is protected.”

Additionally, Mann addresses pretreatment systems as a way to streamline the process. “We offer the MagiCoat

industrialprintmagazine.com

pretreatment system for glass. This system utilizes a flame treatment system along with a spraying system for sprayon primers. It boasts eight stations that rotate individually while going through the system. Each item is flame treated to eliminate debris and coatings put on items such as glass that inhibit adhesion. Any area that can be made more efficient and relies less on the operator is ideal.”

Lambert also points to jettable primer as a game-changing advancement.

“Jettable primer helps in some instances to minimize pretreatment processes before the article gets to the printer. This saves money and time.”

Bolduc says Koenig & Bauer Kammann continues to innovate on the equipment side adding specific features to simplify the process of digital printing.

“We are also working on the consumable side; we have an open ink policy and work with ink suppliers who can bring the most benefit to the complete process. We have recently introduced digital embossing, which could potentially open additional markets for our customers.”

Gonzalez believes general advancements in direct printing to glassware

include the ability to print single items and low-quantity batches without significant setup or associated fees; the ability to print photorealistic images and smooth gradients; evolving primers offer better ink adhesion; and new methods are coming every day, such as UV direct to film, which basically turns the ink into a rub-on sticker with great adhesion.

“Overall, the glassware industry is actively embracing the advancements in DtO printing, recognizing its ability to not only produce superior prints but also to unlock creative possibilities that were previously challenging with conventional printing methods. As a result, digital UV DtO printing is becoming an integral part of glassware customization, offering businesses a competitive edge in delivering high quality and visually stunning products to the market,” says Mann.

Durability Concerns Glassware is typically going to be washed numerous times, so printed images must be durable.

“Washability and durability are a big concern when it comes to glass drinkware,” comments Lambert. The standards are high and when drinkware is

February 2024 [ Industrial Print Magazine ] 21

state-of-the-art primers/ink, and using adequate UV-curing systems. Ceramic inks rely on oven processes to melt pig­ ments into the glass at high tempera­ tures for permanent bond."

Gonzalez adds that while new digital primer formulations help the ink adhere better than previous formulations, the decorated surface may not hold up to multiple runs through the dishwasher.

Larsen feels that with the right reci­ pe-substrate, treatment, ink, cure, and overvarnish-digitally produced products can be very durable. "That said, most companies recommend hand washing because consumers really expect these types of products to last a long time."

"With any piece of drinkware, wash­ ability and durability is a concern. For this reason, it is important to undergo adhe­ sion testing to find the right combination of ink, primer, and pretreatment needed for your vessel," comments Mann.

According to Bolduc, washability and durability is not a concern. "We

subjected to commercial wash cycles, the decoration and color integrity of the decorated glass must remain in tack. "Potential buyers need to make sure they do their due diligence. Most reputable vendors will have third-party test results that can be shared related to successful washing cycles for their ink and substrate combinations."

Gonzalez admits that this can still be a limitation for DtO printing. "Most bulk-produced glassware is screen printed then fired in a long oven to an­ neal the ink in order to provide durabil­ ity. Hand washing is recommended for digitally decorated glassware."

"Glass as a substrate is difficult to print on," notes Maas, "because on a molecular basis it normally lacks bond­ ing points for ink. Here we are looking at two processes which dominate the direct decoration industry-UV ink and ceramic ink. With UV, washabil­ ity and durability depend on proper surface flame pretreatment, applying

have worked for years and continue to perfect the system, with our current process and inks we are able to with­ stand a minimum of 500 dishwasher cycles and many glasses surpass 1,500 wash cycles."

Perrelli agrees, noting that as long as the proper steps are followed prior to printing, there shouldn't be any con­ cern on the ink adhesion. Third-party testing shows that properly prepped glassware can stand up to the rigors of use and 250-plus dishwash cycles.

"Here's the key-operators must be disciplined in following those pretreat­ ment/preparation steps."

Direct to Glass Wineries, breweries, and distilleries are well poised to benefit from the technology afforded by today's UV DtO printers. Print area, ink adhesion, and durability continue to evolve to ensure high-quality directly printed graphics that stand the test of time. /PM

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146 108 160 147 109 148 110 149 150

22 [lndustfia/ Print Magazine J February 2024

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EDS Excelitas Technolooies Coro.

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1ST America Kento Dioital Printinq Koenia & Bauer Kammann Konica Minolta Business Srnutions.

LSINC Mimaki USA, Inc. Mutoh America, Inc. Nexa3D Nikon SLM Solutions

165 112 103 113 104 105 114 153 154

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When and Where UV(lN LED inks are used when print­ ing to corrugated in both single- and multi-pass printers.

With single-pass printing, Ken Ha­ nulec, VP worldwide marketing, EFI, explains that users look for high-speed printing and UV ink with LED curing that offers reliability and productivity.

How is the possible? "UV LED inks do not need drying, which provides an extra benefit in terms of sustainability-the re­ duction in the amount of energy required to cure the ink printed. UV LED also of­ fers other advantages such as virtually zero emissions to the atmosphere, repulp­ ability, and the fact that it can be used in a range of applications. LED curing is superior to traditional arc curing in terms of productivity gains and operational cost advantages," continues Hanulec.

"UV inks are the primary ink used in single-pass printers for corrugated pa­ per in the North American market and much of the rest of the world, excluding Germany who has tried to push against UV suppliers. UV ink and related single­ pass printers can offer a robust, saturat­ ed print that is quite difficult for water­ based inks to duplicate," states Lloyd Kent, VP sales and operations, North America, Kento Digital Printing.

Errol Moebius, president/CEO, IST Americas, believes UV/UV LED inks are favored in single-pass printers in the case of corrugated printing. "The main reason for this preference lies in their curing system. Unlike water-based inks, where multi-pass printing was neces­ sary, UV inks can accomplish the same in one pass due to their instant curing nature. This instant curing attribute of

UV inks allows for single-pass printing, especially for solid, single spot colors."

Fore says that for single-pass digital presses, UV or UV LED is used for three reasons, when a high-end, finished look is required, print quantities are low, and if the substrate is plastic corrugated.

UV inks are also popular for multi­ pass corrugated printing. According to Steve Lynn, director, labels and packag­ ing, Durst Image Technology US, "UV inks are more often seen in multi-pass printers as they address the short-run, corrugated display market."

"UV printing onto corrugated board is used in higher pass modes. One of the reasons is to print more on demand or shortened runs-shorter runs with high­ er image quality and full-color graphics," agrees Jay Roberts, product manager UV printers, Roland DGA Corporation.

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industrialprtntmagazine.com

February 2024 {Industrial Print Magazine J 25

detailed messages and more vibrant color.

That trend, in combination with another important factor-the increase in UV flat­ bed print speeds-have really changed the packaging market," says Roberts.

Technological Advancements

Meeting Demand UV printing for corrugated applications offers a host of features that allow users to achieve success. Manufacturers and converters require dependability, versatil­ ity, and reliability from these printers.

"Users look for dependable curing/ drying of their print with a dependable system that has low to zero maintenance and with components that can be main­ tained by their operators," shares Kent.

Moebius agrees that dependability is a necessary attribute. "The primary re­ quest revolves around achieving a con­ sistent and repeatable process. As these systems utilize 100 percent solids, the daily production shouldn't be affected by moisture or weather conditions. Both durability and consistency are crucial factors, and as time progresses, costs­ comparing water-based, mercury, and LED curing systems-will inevitably gain more significance."

Versatility is another consideration, more so for print service providers over manufacturers. "Print providers using a

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Kento Digital Printing

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UV curing system to produce corrugated work are most concerned with versatil­ ity; print providers want to accomplish as many applications as possible, like print­ ing on plastics and papers, with as little equipment as possible for profitability's sake," adds Lynn.

Hanulec lists reliability, reduced energy consumption, durability, resis­ tance, and flexibility as main requests from users.

A compact device is also advanta­ geous. "Being more compact means a user can fit a machine on their plant floor and requiring less power may be the fac­ tor that opens a path to place a single-pass printer in their facility that much longer machines cannot do," explains Kent.

According to Ken Parsley, product ap­ plications engineer, Mutoh America, Inc., the real goal is fast print speeds at an ac­ ceptable quality level.

"Today's packaging buyers want to achieve greater marketing value with their boxes, and as a result, we see pack­ ages that feature increasingly complex,

�llllili'ecll See page 22 for more information.

Website

baldwintech.com

Durst lmaae Technoloav US

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Konica Minolta Business Solutions U.S.A., Inc. Mutoh America, Inc.

Roland DGA Corporation

26 [lndustfia/ Print Magazine J February 2024

efi.com

kentodigitalprinting.com

kmbs.konicaminolta.com mutoh.com

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UV/UV LED inks-and by extension the UV curing systems in place-continue to advance.

Arc curing systems are being re­ placed by LED curing "due to economic benefits, primarily through productivity increases and operating cost advantag­ es," shares Hanulec.

"LED technology has been integrated into digital decorating from the start, creating a natural connection. Over time, LED systems have significantly im­ proved, becoming more potent and offer­ ing a wider range of parameters that can be monitored, enhancing process control.

As the cost effectiveness of power con­ sumption between LED and traditional UV becomes more critical, LED options might gain more traction. However, the expenses related to consumables also need to align with this shift, gradually becoming a more influential factor over time," foresees Moebius.

The transition to LED curing lamps is a huge benefit to corrugated. "In par­ ticular, since corrugated deformation is amplified by heat, the low heat generated

by UV LED presents advantages in the corrugated space. For many users, cold curing allows them to print on a much wider range of substrates, both thick corrugated and thinner microflutes," ex­ plains Hanulec.

"With a strong move to advance from UV to UV LED inks, systems for curing LED inks provide less heat on the cor­ rugated surface, which helps the board remain flat and not be affected by heat," continues Lynn.

1. Kento Digital Printing's hybrid single-pass printing technology offers printing to corrugated cardboard.

2. The Roland IU-1 OOOF is a high-productivity UV fiatbed printer that outputs to corrugated.

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Parsley adds that UV LED curing sys­ tems also operate much closer to the vis­ ible spectrum, which greatly reduces the risk of eye damage.

Besides the curing systems, the ink itself is changing-in a good way. "UV inks designed for corrugated are flexible enough for folding and strong enough for creasing. They are fully repulpable and recyclable and contribute to the circular economy of corrugated," shares Hanulec.

"With so many ink manufacturers making UV inks and primers for single­ pass machines, the competition is quite high and ink costs are being driven down.

This has to continue for a greater adop­ tion of single-pass machine purchases to happen in the ultra-competitive corru­ gated packaging industry, especially for companies that run a lot of boxes and not as much display work," suggests Kent.

Water-Based Side Despite advancements in UV technology, water-based inks are an important player in digital corrugated board printing.

"The dominance of water-based inks is due to their cost effectiveness, ease of application, and the availability of equip­ ment for curing. Additionally, for lower resolution printing on corrugated surfac­ es, especially for heavier coverage areas, cost sensitivity is a significant factor influ­ encing this choice," notes Moebius.

Health and recyclability are two main reasons. "Recyclability is a large motiva­ tor to print with water-based inks. Water­ based inks play a critical role in food packaging as it relates to migration, and that is a great opportunity for packaging print providers," says Lynn.

Flexibility and longevity are other fac­ tors to consider. "Water-based inks have more flexibility than UV inks. A water­ based pigment ink has a longer longevity than water-based dye inks. In addition, water-based inks can be FDA approved for direct and indirect food contact," ex­ plains a representative from Konica Mi­ nolta Business Solutions U.SA, Inc.

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Hanulec doesn't believe "waterbased inks dominate digital corrugated printing, at least not within most state­ of-the-art technology, which is industrial single-pass printing. The number of in­ stalled machines using UV technology is higher than the water-based lines-ex­ cluding China."

While Hanulec admits that water­ based inks are well known and valued in the packaging industry-primarily for their inexpensiveness and lack of photo­ initiators-UV-curable inks still provide advantages in terms of speed, drying time, energy consumption, and abrasion resistance when it comes to high-produc­ tivity printing.

"Water is a very safe carrier, but it needs to be absorbed or evaporated to dry. This is not so much a challenge in slower consumer inkjet printers, but for high-speed printers, sophisticated and high-energy drying systems are required, often along with a primer/pre-coat on the substrate that controls the dot gain of the ink droplets as they are dried. It also limits what additives can be added to the ink to increase performance like binding to cer­ tain substrates, causing many water-based ink systems used for corrugated printing to use a post-coat to protect against abra­ sion and scuffing;' continues Hanulec.

Another disadvantage to water-based ink is the required plant floor space.

"Plant floor space needed for water­ based systems is tremendously higher because of the extended drying sections of the machines and energy costs are extremely higher because of these large drying sections needed to evaporate the water for the ink;' states Kent.

Moving Forward Pushing users toward UV printing for corrugated is a challenge, but one that can be overcome.

First off, it's important to combat any misinformation out there. "Most provid­ ers of water-based inks promote to the industry that you cannot use UV inks in

food pack­ aging. This is not true. All of the major ink suppliers, including those who provide flexographic inks to the corrugated industry will tell you their UV inks are well suited for food packag­ ing. These ink suppliers continue to drive the cost down as has happened in other digital industries and this helps advance single-pass digital in the corrugated indus­ try," explains Kent.

"Educating end users about the practi­ calities of using UV or LED technology is essential. This includes providing insights into the operational reality of these sys­ tems. While UV inks might incur slightly higher costs-around ten percent, they are more efficient in usage. Additionally, they entail lower energy costs, among other benefits. Hence, there's a need for an edu­ cational initiative to highlight these advan­ tages," admits Moebius.

Parsley notes that care needs to be taken in regards to the corrugated media itself. "In my experience, printing on cor­ rugated is more about the media than the print system. Maintaining the media in a manner that allows it to remain flat and straight is the biggest challenge. UV LED machines are very capable of printing on this substrate if it is capable of lying flat.

A strong vacuum on a flatbed device can correct for some warping but not all."

Learn more about UV/UV LED print­ ers used for corrugated by tuning into our webinar on the topic. Visit industrial­ printmagazine.com/webinars to access our archives. 1PM

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