Digital print technologies support directly decorating cylindrical objects, from drinkware like wine glasses and aluminum beer cans, to sporting goods such as baseball bats or even writing implements like pens and pencils.
Our cover story, PrintRightRound, jumps into the twodifferentmethods available-dedicated devices and fiatbed printers equipped with special rotaryattachments. Thechoicebetweenthetwoisdeterminedbasedon the user's cylindrical printing needs and aspirations-as well as budget.
Another topic supported by digital printing technologies? Corrugated packaging. With advancements in printhead technology, ink, and automation, inkjet is slowly but surely maturing in this space. Read more in AllPackedUp.
Rounding out the issue are columns on automating the finishing end of the corrugated printprocessandsoftware security for additive manufacturing, as well as a chart listing cutting tools used for corrugated board.
Melissa Donovan, Editor
�-RIAL 9PRINT
INDUSTRIALPRINTMAGAZINE.COM
Volume 12,Number3
EDITORINCHIEF
ThomasTetreault
978-921-7850
EDITOR
Melissa Donovan mdonovan@rockportpubs.com
ASSOCIATEEDITOR
Cassandra Balentine cbalentine@rockportpubs.com
ARTDIRECTOR
Sarah M.White swhite@rockportpubs.com
WEBEDITOR
Melissa Mueller
CONTRIBUTORS
Pete Basiliere, Olivia Cahoon, Kemal Carr, Maria Conrado, Mark Hanley, MelindaTetreault
PHOSEONUV CURINGSYSTEMS FROM EXCELITASAVAILABLEWITH MODBUS TCPCOMMUNICATIONPROTOCOL
Excelitas announces the availability of enhanced Phoseon UV LED curing systems with newly integrated Modbus TCP communication protocol for high-speed dataexchangeand remoteaccess.
This significant upgrade to Phoseon products' robust control architecture allows faster, more intelligent communication with FireJet ONE, FireJet FJ100, FireJet FJ240, Fireline FL400, and FireLine FL440 UV LED curing systems. Customers now have the flexibility to choose between RS485 or Modbus TCP communication protocols-ensuring compatibility with a range of automation and process controlenvironments.
The new ethernet-enabled products retain theprovenbenefitsofPhoseonproducts,including long product lifetime powered by patented semiconductor light matrix technology, superior uniformity, efficient thermal management, and seamlessintegrationwithexistingsystems.
The Phoseon FireJet and FireLine series from Excelitas offer scalable UVLED curing solutions with a variety of cooling options, wavelengths, and irradiance levels. With more than 200,000 Phoseon units shipped and over two million hours of LEDtesting, Phoseon products set the standard for high performance, energy efficient, and environmentally sustainable UV curing.�NFD#161
THERMWOODUNVEILSTHEMAX5
ThermwoodCorporationreleasesitslargescalefive-axisCNCmachine,theThermwood MAX5. Engineered for industries that require size, strength, and precision, the MAX5 redefines what's possibleinlargeformatfive-axisCNCrouting.
Designed totacklethe mostdemandingthree-dimensional (30) machining applications, the MAX5isidealforproducinglargetoextremelylargecomponentsforaerospace,marine,automotive, and construction. From massive molds to complex structural elements, the MAX5 delivers unmatchedpower,precision,anddurability.
TheMAX5isaheavy-duty,high-clearance,five-axisCNCrouterbuilttoperforminthemostextrememachiningenvironments.Utilizingadvanced30modelingand FiniteElementAnalysis,the MAX5 is structurally optimized to maintain peak performance even during complex, high-stress, multi-axisoperations.
Boston Industrial Solutions, Inc. introduces Natron504NSeriesUVinkforEpsonXP600,TX800, DX5,DX7,andDX10printheads.ThisUVLEDink isengineeredtodeliveroutstandingperformance on both hard and semi-flexible materials. Additionally,theNatron504Nisfullycompatiblewith any printer equipped with the aforementioned Epsonprintheads.
Natron504Ninkjetink representsa commitment to innovating and bringing cutting-edge technologytotheprintingindustry.Itguarantees vibrant, long-lasting prints whether printing on packagingmaterialorrigidprints.�NFD#162
MUTOHINKREGULATION COMPLIANT
Mutoh America, Inc. announces that its ink lines-US-11, UH-21, and MP-31-are now compliant with U.S. toy safety regulations, including the Consumer Product Safety Improvement Act (CPSIA) andCaliforniaProposition65.Thiscomplianceallowsforthesafeuseof Mutohprinters andinksintheproduction ofgoodsintendedfor use by children and in sensitive environments. Whilenotaformalcertification,theinksmeetthe chemical content requirements outlined in both CPSIAandProp65.�NFD#163
1. The Phoseon Firelineseries fromExcelitas offersscalable UV LED curing solutions. 2. The Thermwood MAX5 features a 17 horsepower liquid cooled spindle.
CONSTANTVIGILANCE
ProtectingAMwithSoftwareSecurityMethods
by IndustrialPrint Magazine Staff
When three-dimensional (3D) printers are connected to the internet, they become susceptible to cyberattacks.
"Thisleavesconsumerandcorporatenetworks vulnerable to theft of private data, ransomware attacks, and disruption to normal course of businessand life.Employingpropersecuritypractices can prevent these attacks that result in significant costs to corporations and consumers," explains Christopher Stricklan, CEO/co-founder, Kraetonics, LLC.
Implementing software with real-time monitoring, authentication, encryption, and other security features helps proactively manage risk.
Importance of Security
Additive manufacturing (AM) requires safeguards that protect vulnerable files and data.
Whilethishasalwaysbeentrue,withAMexpandingbeyond prototyping and into "producing critical components for aerospace, defense, medical, and energy sectors," it is now more critical than ever to protect the process, according to Brent Stucker, chief scientist, Nikon SLM Solutions.
''Asmachinesbecomemoreconnectedforefficiency,remote monitoring, and data-driven optimization, they also become more exposed. Every
security for AM is important because of the many attack vectors, for example IP theft and the insertion of faults into devices. "Software is both the cause of those attack vectors and with secure, end-to-end solutions, it can protect against them."
Looking particularly at IP, Marcellus Buchheit, president/ CEO, Wibu-Systems USA Inc., says protecting digital files for 3D printing is critical for safeguarding IP, preventing unauthorized use, and maintaining data integrity.
- Marcellus Buchheit, president/CEO, Wibu-Systems USA
� ing files are more often than not distributed to the various stakeholders via the internet. In many cases, that object is only one part of a finished product assembled by another agent in that process-an integrator
"From concept to the printed object, many stakeholders contribute to the AM process. The actual digital design of the printed object represents or contains the IP of its maker, and today, those digital printconnected machine becomes a potential entry point for cyber threats that can compromise intellectual property (IP), alter part geometries, or even affect the material properties of missioncritical components," continues Stucker.
Andre Wagner, CEO, Authentise,sayssoftware
1. Flows workfiow management from Authentise.
or perhaps a vendor. In other cases, the actual 3D printing will be handled by a third party service provider. At every step in the process, the digital IP needs to be protected against theft, piracy, and tampering, but still be readily available for legitimate agents to use, process, and reprocess,” continues Buchheit.
There are so many different parts of the 3D printing process that if one section is interfered with, the whole process is ruined. For example, “in metal AM, the digital thread—CAD, process parameters, scan strategies, and build data— holds the recipe for performance. If even one variable is tampered with the end part could fail without warning. That’s why software security isn’t just an IT concern; it’s a manufacturing integrity concern. Secure AM workflows protect
IP, ensure traceability, and guarantee the safety and reliability of printed parts,” states Stucker.
Another example, at 3YOURMIND the company works with defense organizations where securing the production chain is critical. “Data in the hands of malevolent actors could give them an advantage; such as sabotaging parts by altering the print files before production,” shares Felix Bauer, CTO, 3YOURMIND.
“Secure AM software is vital to protect IP, ensure design integrity, and prevent malicious alterations. The uptime of machines is the most vital aspect in a manufacturing environment. There has to be a complete 360 degree perspective on all aspects of security in all layers,” says Ajay Bharadwaj, head of software development, Intech Additive Solutions.
Type of Software
End-to-end workflow software is one defense against vulnerabilities. Standalone solutions, like in-process monitoring, authentications, and encryption are also useful.
“The system is as secure as the most vulnerable point. So all aspects should be considered in terms of security,” admits Bharadwaj. This means many different software solutions with multiple purposes can be considered, for example, counterfeiting of spares, real-time monitoring solutions like tampering of parameter sets for each print, multistage authentication of parameter sets, end point security, encryption of print files, secure transfer, and audit systems.
According to Stucker, important layers of software security in AM include
access control and authentication systems, which restrict and log access to machines, software platforms, and files, ensuring only authorized personnel can make changes. Another is end-toend encryption; data is protected as it moves through the AM workflow—from design to print to inspection. Real-time monitoring and intrusion detection helps track unusual machine behavior or file access patterns that might signal tampering. File integrity monitoring ensures that build files haven’t been modified since approval. Audit logs and version control provide traceability for compliance and forensic analysis in case of a breach.
“These systems work together to create a resilient and transparent AM environment, giving manufacturers peace of mind and auditors clear visibility,” adds Stucker.
File encryption, digital rights management solutions, and access control systems are also used to protect 3D printing files, says Buchheit. He also notes Advanced Encryption Standard is an industry standard tool used for secure file transmissions. Rivest-Shamir-Adleman uses public key encryption schemes while end-to-end encryption ensures that only authorized parties can access the file during sharing or storage.
“Combining two or more of these mechanisms greatly enhances protection of the IP embedded in the 3D printing files,” continues Buchheit.
Tools like binary diversification (BINDIV) provide passive protections to computer systems. “Kraetonic’s goal is to support manufacturers to integrate BINDIV into their development operations pipeline to prevent bad actors from being able to massively exploit their systems,” explains Stricklan.
Many software providers collaborate to help with security. For example, Authentise is part of a government-funded CYMANII project. “It proves that, by combining integrated end-to-end workflow software with separate in-process monitoring suites— we work with Addiguru in this case—we can radically reduce the errors inserted in the process thanks to triangulation of machine data, monitoring data, and Authentise’s workflow data,” explains Wagner.
Stricklan points out that the responsibility of security should be on the printer manufacturers, however consumers can also take ownership. “Consumers can employ network intrusion detection software, firewalls, and anti-virus products. These solutions are reactive and not proactive, but provide some level of protection and situational awareness. The downside is that they can be expensive, difficult for consumers to deploy, or not supported by the AM platforms. The two most important things a consumer can do is to make sure to perform regular firmware updates when they are provided by the manufacturer and choose a manufacturer that is dedicated and proactive in providing secure products.”
The 3D printer’s firmware should support secure protocols for full traceability. “Ideally, 3D files are decrypted by the printer just before the print. That way, it should not be possible to alter the file or reprint the file without authorization. However, there are some challenges with that. Currently, print vendors
lack a standard for secure protocols. In addition, 3D files often need to be preprocessed before the print. To ensure full security, the print preparation must be performed by the IP owner and not by the print operator, which can be a challenge,” admits Bauer.
Security Musts
Every 3D printing solution should regularly maintain certain security standards.
According to Buchheit it is important to balance between integrating layers of security versus ease of use for the operator. “Achieving the optimal level of security will provide the necessary protections for the application while not overly restricting the end user processes. Ideally, built-in security solutions should provide end-to-end encryption of the digital print file, from design to printed object, as well as ensuring secure transmission of the encryption keys required to decrypt the file for printing.”
Wagner says standards like ISO/IEC 27001:2022 or NIST SP 800-53 must be followed. CMMC is necessary. Furthermore, he states that a software solution in his opinion isn’t viable unless SSO and on-premise compatibility are standard.
Stucker lists role-based access control, secure file transfer protocols, audit trails and logs, encrypted storage and communication, real-time anomaly detection, and firmware validation as important considersations.
Bharadwaj’s must haves are authentication of usability, data encryption, integrity checks, and end point security. He says also helpful is a feature that can limit the number of times a particular part can be built. This prevents unauthorized manufacturing of certain components and limits growth of grey market.
Files encrypted both at rest and in transit, a permission system to allow only authorized personnel to access the files, and software protected using industry standards and practices are all things Bauer recommends as necessary.
For nice-to-have security features, Stucker suggests biometric authentication, air-gapped printing capabilities, integration with enterprise cybersecurity systems, self-healing software that can isolate compromised modules, and automated alerts with artificial intelligence (AI)-based prioritization.
Also on the wish list, “a zero-trust production chain with end-to-end encryption from CAD tool to printer. However, this is difficult to achieve. In reality it is still often the printer operator or service bureau that need to be trusted by the IP owner,” continues Bauer.
Manufacturers of AM platforms should conduct firmware updates to ensure security is up to date, according to Stricklan. “Manufacturers need to regularly perform red teaming assessments of AM platforms to identify any vulnerabilities. They should provide firmware updates as needed to close known vulnerabilities reported to the cyber vulnerability enumeration database or ones they found internally during their red team assessment process.”
AI in Security
AI plays many roles, and one of them is in security. It’s helpful in quickly detecting when something is amiss.
“AI helps identify intrusion events by detecting anomalies,” suggests Wagner.
Ideally, AI functions in a proactive role. “By analyzing vast streams of machine behavior, user activity, and data flow, AI can identify subtle deviations that might escape traditional rule-based systems. For example, a shift in laser parameters that doesn’t match the original build file, or access from an unusual IP address, can be flagged instantly,” explains Stucker.
Bharadwaj agrees. “AI can be a boon in terms of identifying threats such as anomaly detection, predictive threat detection, and even automated action.”
Furthermore, “AI-driven behavioral analysis and predictive analytics can
flag deviations in typical user behavior, such as unusual login locations, access times, or activity patterns that may indicate data compromises. AI models based on historical data are used to predict future threats and vulnerabilities, allowing organizations to proactively strengthen defenses before an attack occurs,” says Buchheit.
“Using AI to augment our ability to solve problems faster will make developers and analysts faster and more efficient,” asserts Stricklan.
Examples of this include vulnerability assessment and network intrusion detection. “Teams have performed custom training of neural network, tensor flow, and large language models to help identify vulnerabilities in source code and machine code to aid in the discovery of vulnerabilities before software is released. Network intrusion detection is an area where AI excels by quickly identifying patterns of network communications that differ from the norm. Both of these capabilities augment a human’s ability to identify errors early to help prevent exploitation of systems and networks,” adds Stricklan.
“Manufacturers should employ AI models to assess their platforms for possible vulnerabilities, determine if bad actors are attempting to infiltrate a network, and use sidecar capabilities to help improve the security of their software. The proper use of AI can be a significant benefit when used effectively,” says Stricklan.
Software Security
Vulnerabilities range from bad actors to ransomware. They are now all common in 3D printing. Implementing software with real-time monitoring, authentication, encryption, and other security features helps proactively manage any risk. It’s up to both the user and hardware provider to stay vigilant as AM becomes more reliant on the internet. IPM
CORRUGATED
RAMPING UP FINISHING
Automating the Corrugated Process
by Melissa Donovan
Automation takes digital printing to corrugated board to the next level. Digital finishing components automate the back end—and even material handing mechanisms that move the media both at the front as well as the end of the process benefit from evident efficiencies.
Due to the nature of corrugated board—it’s bulky and subject to warping—maintaining a consistent print and finishing process with little to no manual handling is key to processing large production runs as well as shorter, more customized orders.
Importance of Automation
Whether inline, near line, or offline, automated finishing and material handling is an important part of the corrugated digital printing equation. It is helpful to rely on automation to move these large sheets of media before and after the printing process.
According to Randi Kerkaert, product manager, Summa, “automation, whether inline, near line, or offline, is crucial in modern corrugated digital printing. It enables both personalization and standardization, reducing the minimum volume required for customization.”
“Automation of the corrugated print process is crucial for maximizing efficiency, reducing labor costs, and ensuring consistent quality,” explains Martin Thornton, executive sales manager, Zund America, Inc.
Consistency across every finished print is imperative. “Automation ensures consistency in both quality and production speed. For instance, the 100th or 1,000th sheet is
Automation, whether inline, near line, or offline, is crucial in modern corrugated digital printing.
— Randi Kerkaert, product manager, Summa
processed with the same precision, accuracy, and efficiency as the first sheet eliminating variations caused by human errors. This is especially important in corrugated digital printing, where maintaining uniformity across large or short runs is key to meeting customer expectations both in quality and lead time,” explains Nimil David, product manager, robotics and automation, Kongsberg Precision Cutting Systems. Specifically, automating the front end of the process “streamlines job preparations, reducing setup times and errors, which is essential for handling short runs. Automated 1. The Kongsberg Feeder & Stacker combination speeds up short-run production by eliminating manual handling bottlenecks and reduces both material damage and waste, without additional labor costs.
material handling eliminates bottlenecks in loading materials into printers, ensuring consistent throughput,” shares David.
On the back end, David says “automation guarantees effective and efficient stacking, preventing bottlenecks that could slow down production. In order to achieve a smooth workflow with minimal manual intervention, performance of the automation machine is critical. For instance, the stacker should be able to pick up all cut details to avoid any disruption of the workflow.”
Automating both the delivery and unloading of media is key to achieving maximum productivity and quality. “Large format boards are easily damaged when manually fed to printers and cutters. Automation not only improves
throughput but also reduces waste and improves the quality of the final product,” explains Rick Stark, owner, Infinite Motion Control, Inc.
It’s important to point out how influential automation is today in the labor force. “With rising labor costs and a shortage of skilled operators, front- and back-end automation ensures a 24/7 production workflow, offering a significant competitive advantage, especially in high labor cost markets,” adds Kerkaert.
“Having the correct machine to get this done quickly and efficiently is vital to a well-functioning shop. Automating the cutting is not only more efficient but necessary for high production or complex contoured cuts,” admits Jason Friesen, national CNC sales managersign segment, Laguna Tools.
Board Talks
Automation can be useful no matter what material is being processed, but corrugated board is a prime candidate.
“Corrugated boards are generally large and bulky, especially in larger quantities, making manual handling inefficient and labor intensive. Automated systems, such as robotic loaders, stackers, and conveyor systems reduce the need for manual intervention, improving productivity and consistent output quality,” says Thornton.
Due to the physical nature of corrugated media, it is susceptible to issues like warping and moisture variations. “This can significantly affect the quality of the final product. This also poses challenges to automated material handling, therefore, automation solutions should
be developed in a way that mitigate these challenges,” explains David.
The size and structure of corrugated board makes it nearly impossible to manually load well. “As printing speeds increase it is no longer possible to manually load large format boards to match the throughput of the printer. Automation in
the corrugated industry is essential in reducing human exposure to repetitive motion task injuries. Automatic feeding and stacking virtually eliminates the need for human touch,” says Stark. According to Keith Verkem, national sales manager/senior product manager, Colex Finishing Solutions Inc., “because
corrugated is usually knife cut it is ideal for conveyor belt systems to load and offload the material.”
Friesen seconds the advantage of using a knife for cutting corrugated. “This material is perfect for CNC’s equipped with a knife system. Corrugated board can be cut quickly and efficiently whether it is straight cuts or complex contoured cutting,” says Friesen.
“Pieces of corrugated board require precise cutting, creasing, and scoring to ensure proper folding and assembly. Automation ensures consistency and accuracy, reducing waste and ensuring structural integrity in packaging applications,” summarizes Thornton.
Options Aligned
Automated finishing and media handling components can run inline, offline, or near line to a digital printer. Each option has its advantages as well as disadvantages.
Inline
In this scenario, finishing and media handling mechanisms are connected directly to the printer.
“Inline pallet-to-pallet processing stands out for its efficiency, requiring the fewest touches and even enabling lights-out production,” admits Stark.
2. Laguna Tools’ Smart Shop MT Elite is a versatile router platform equipped with Fanuc controls that enable seamless operation, precise movements, and unrivaled reliability. 3. Zünd offers multifunctional, highly modular, and customizable cutting solutions for corrugated.
Thornton says a seamless workflow should eliminate the need for manual intervention between printing and finishing. At least in theory, there is a faster turnaround since printed boards move directly into finishing, eliminating any handling delay.
“Inline finishing ensures seamless alignment between print and finishing processes, improving quality control,” notes David.
The issue with inline is speed mismatch, admits Thornton. “More often than not, digital printing and finishing processes differ in speed, which leads to inevitable slowdowns in one or the other.”
Integrating finishing directly into the printing process also creates dust accumulation, which requires continued maintenance, according to Kerkaert.
Another disadvantage to inline is it limits flexibility. “Inline systems are designed for specific processes, making it harder to accommodate complex finishing needs—as opposed to e.g. simple slitting operations,” notes Thornton.
There is higher risk when investing in a fully connected, inline process. “If one part of the system—printer, cutter, automation—fails, the entire production line may be affected,” cautions David.
According to Thornton, the best fit for inline is a high-volume, standardized corrugated packaging operation with minimal finishing complexity.
Offline
When finishing and material handling tools are kept completely separate from printing it is referred to as offline.
Maximum flexibility is the biggest advantage here. “Different finishing equipment can be used depending on job complexity. Each system—printing and finishing—operates at its maximum speed, avoiding slow downs of one or the other,” shares Thornton.
“Offline provides the highest level of flexibility, making it ideal for complex or high-value projects. However, it requires additional handling, which may slow down production,” agrees Kerkaert.
Lack of connectivity is also a disadvantage in offline configurations. “Offline requires manual handling or additional automated transport systems, adding potential labor costs and delays. There is slower overall production workflow compared to inline/nearline solutions,” states Thornton.
AI IN CORRUGATED
Artificial intelligence (AI) influences corrugated printing and finishing, powering the automated process.
“AI is already making an impact on automated finishing through intelligent proofing, quality control, and optimization in nesting and production processes. However, we are still in the early stages, where experimentation is widespread, but the full productivity benefits are yet to materialize,” admits Randi Kerkaert, product manager, Summa.
Kerkaert cites Gartner’s Hype Cycle. “AI in corrugated printing is currently in the ‘inflated
“There is a longer overall turnaround time and space restrictions could be possible as additional storage and floor space might be needed to accommodate materials from each stage,” suggests David.
Near Line
Finishing is separate but close to the printer in a near line configuration, and may be connected via conveyors or some other means of automation.
Reduced downtime is a positive. “If one part needs maintenance, the other can continue operating independently,” says David.
Near line finishing balances speed and flexibility. “It allows for automation without fully integrating into the print line, offering the ability to handle multiple job types efficiently,” explains Kerkaert.
A big advantage here is that if you are considering adopting more complex
expectations’ phase. Over the next two to three years, as businesses refine AI applications and integrate them into real-world production, we will reach the ‘plateau of productivity,’ where AI delivers tangible value in automation and efficiency.”
In regards to material handling, Nimil David, product manager, robotics and automation, Kongsberg Precision Cutting Systems says, “with ample data and predictive tools, AI enhanced technologies can potentially be used with high-resolution cameras, sensors, and with machine-learning algorithms. The technologies can also scan and analyze the corrugated board for
finishing methods beyond slitting operations, it is easier to implement without influencing the printing process, notes Thornton.
A challenge with near line is that it “requires sophisticated technology and space for additional material handling and transport systems,” admits Thornton.
The best fit for near line is “mediumto high-volume production with varied job complexity, where automation is a priority, but inline finishing is not practical,” recommends Thornton.
Stark believes near line offers the best of both inline and offline. “Near line processing retains many advantages of inline while adding the capability to store or accumulate material overflow, which when automated can be seamlessly reintroduced into the workflow when feed rates between printing and finishing are not aligned.”
See page 21 for more information.
114 Summa summa.com
115 Zund America, Inc. zund.com
the warp and automatically adjust the settings for the automation systems.”
This isn’t the only possibility. AI is also used “to detect a defective board, so that it can be prevented from being digitally converted and avoid loss of time and directly moving to the next sheet,” adds David.
“AI-powered smart scanners and sensors help detect what the human eye may miss. AI-powered readers also help with tracking of completed jobs and allow real-time production feedback to customers and management,” adds Rick Stark, owner, Infinite Motion Control, Inc.
Future of Finishing
The power of automation continues to expand. It is only logical that its integration into the entire print process closes the gap, moving from offline to near line and eventually inline.
“Automation in near line or offline finishing remains highly important to keep up with the high-speed digital printing process. With further innovations in robotic material handling automation—the critical component that links the two systems—it will no doubt be possible in the future to create flexible, yet fully integrated inline production workflows,” admits Thornton.
Automated inline finishing solutions meet the needs of the industry. “With industry trends favoring shorter runs and rapid delivery, inline and near line solutions are becoming increasingly essential,” states Kerkaert.
To keep pace with the increasing speeds of digital printing and finishing components, “we see the need for automation that allows for lights out production,” notes Stark.
“Looking ahead, it is crucial to stay aligned with emerging corrugated production methods and industry innovations and to have a proactive and adapting approach to these advancements, future-proofing our business,” concludes David. IPM
AUTOMATE THE BEST CHOICE FOR CORRUGATED
122 BrausseGroup
brausse.com
123ColexFinishin,Inc.
colex.com
124 CarrusstemsB.V.
corrusstems.com
125ElitronAmericaInc.
elitron.com
Graphco
rahco.com
mimakiusa.com
sunautomation.com
133 VisionEngravingandRoutingSstems
visionenravers.com
134ZundAmerica,Inc.
zund.com
"The two systems are very different, with the cylindrical printer really being designed for production-level volumes and thecapitalcostthat goes with it.You will likely find the inks designed for specific applications, hence the system may be focused on specific products such as glass bottles or cans," notes Paul Edwards, VP of the digital division, INX International Ink Co.
Dedicated Cylindrical Printing
One way to printto cylindrical objects is with a dedicateddevice.
Edwards lists speed as the top advantage of this method. "Depending upon the design of the system, you can get throughput up to around 500 products per minute. However, it is likely that people are more often running at
speeds of around 100 to 300 products per minute."
Another advantage ofprinting directlyto cylindrical objects with a dedicated printer is that it creates a stronger bond to the substrate, as long as the material is compatible, shares Rick Marcelo, technical director, Arcus Printers. "You also get faster print speeds with this method. Some dedicated cylindrical printers even have the ability to print on different surface angles, like a sloped cup instead ofjust a perfect cylinder."
Quality is another perk. "The quality of the product can be very good from a color and detail perspective, and the printing finish looks nice and smooth. Depending upon the number ofchannels in the printer, a range of colors and features are available," offers Edwards.
MichalePerrelli, director ofsales, Innovative Digital Systems (IDS), says direct cylindrical printing offers the ability to print in full color range with special effects and seamless full-wrap design, unlike pad printing, silk screen, label, or offset print solutions.
"Digital print is of course also synonymous with a wide color gamut, and thiscarries through toDTOdigital printing," sharesJessicaMakrinos, marketing manager, Inkcups.
DTO UV inkjet printers typically print with CMYK, white, and varnish, but Makrinos says Inkcups' Helix range of cylindrical printers have the ability to add light cyan and light magenta. ''Additionally, different techniques with varnish, varying ink opacity, or base ink layers make it possible to produce a range
CFXseries
The CFXSeries is a professionalflatbed cutting plotter built for high-speed productivity. A multi-tool head reduces changeovers, boosting efficiency. Now compatible with EngView Systems, it enables a powerful packaging design-to-cut workflow-ideal for folding cartons, POP displays, and custom packaging applications.
of striking special effects that wouldn’t be possible with other printing technologies—from etching and luster to mirror print and stained glass effects.”
Perrelli points out that a dedicated cylindrical printer can efficiently print variable data, allowing for fast and accurate customization processes as well as reduced minimums.
Lon Riley, founder and principal collaborator, DPI Laboratory, says some dedicated cylindrical print machines can have a larger ink throw and more easily accommodate and level obscure shapes, as compared to flatbed rotary systems. They are also fast in one-up printing.
Direct printing eliminates the need for additional production steps, simplifying the workflow, adds Marcelo.
There are limitations to consider. Dedicated cylindrical print machines are still quite expensive and only perform that one rotary action, adds Riley.
Emilio Rangel, UV product manager, Mutoh America, Inc., agrees, noting that these machines are also typically restricted to cylindrical items, making them less adaptable for businesses that need to print on a variety of substrates. “They cannot often accommodate flat or irregularly shaped products, requiring companies to invest in multiple printers to meet diverse printing needs.”
Edwards also sees potential challenges with adhesion, ink laydown quality, and system reliability. “Given the nature of the system, it is not very tolerant to losing nozzles without impacting the
150Arcus Printers arcusprinters.com
151DPI Laboratory dpi-lab.com
152Inkcups inkcups.com
153Innovative Digital Systems ids-digital.com
154INX International Ink Co. inxinternational.com
155LSINC Corporation lsinc.com
156Mimaki USA, Inc. mimakiusa.com
157Mutoh America, Inc. mutoh.com
158Roland DGA Corporation rolanddga.com
image quality. This is where the importance of ink design and system understanding plays a role.”
A substrate may require additional primers to promote adhesion, and in some cases, it may be incompatible, meaning the ink won’t stick, admits Marcelo.
Flatbed Options
In addition to dedicated cylindrical printers, UV flatbed printers with rotary attachments allow for printing onto or around cylindrical objects.
Cost is a consideration. Perrelli notes that flatbeds may be more affordable than a dedicated cylindrical press.
Versatility is also an advantage, as flatbed printers offer the ability to print on a variety of cylindrical objects such as mugs and bottles, without needing a specialized machine. “You can convert back and forth between cylindrical and traditional flatbed goods. You can easily switch between printing on cylindrical objects and flatbed items. A print shop can quickly adjust settings to accommodate different objects or projects, allowing for efficient transitions from one print job to another,” adds Perrelli.
“These devices can print on flat substrates and cylindrical objects, making them ideal multi-purpose investments,” agrees Philip Chu, UV printer product manager, Roland DGA Corporation.
Bullington notes that flatbed printing may have a quality advantage if the media contains a flat surface that deviates from the swept cylinder by more than the jetting distance.
Printing directly to the substrate using a desktop flatbed printer can also result in a strong bond, provided the material is compatible, says Marcelo. “There are no extra production steps required, and you can achieve photo-quality prints with unlimited color options.”
Similar to dedicated presses, Marcelo points out that primers or specific surface
1. A kebab option is available on the Mimaki UJF Series printers to support cylindrical printing.
preparation may be needed to ensure good adhesion.
Hugo Gonzalez, senior segment specialist, industrial products, Mimaki USA, Inc., points out that printing directly to a cylindrical object on a flatbed printer enables printing more objects at one time, especially using a jig. "In this case, aprintercan reasonablyprinta full table in about the time it would take one or two full wrap prints on a kebab tool."
Rangel admits there are some limitations primarily with object shapes and sizes. For example, cylindrical objects with handles-like coffee mugs-are unable to run through a rotary due to clearance restrictions. "Despite these limitations, a rotary attachment significantly expands the range of products users can customize."
Riley agrees, adding that once you level it, the process is repeatable
TEQUILA
TRUENO
diverse markets and need to accommodate various product types.
If quality is essential, Bullington admits that the image quality of a cylindrical printer on cylindrical and pseudocylindrical media will always be better by following the curvature for a consistent print gap than what can be achieved on a flatbed where the print gap varies. However, if the media contains a flat surface and it is the only surface to be decorated, and rotary printing is only one of many a flatbed solution may be simpler to use. functions that flatbeds can perform. "This will depend on the media and how "You can make very high-quality rotary the cure lamps interact with the support prints and still have the benefit of a fixtures for the media as to how successprinter that can customize promotional ful one will be." products, produce signage, and every- A dedicated cylindrical printer is betthing else that these machines are de- ter suited for printing on multi-planed signed for. surfaces or objects with angle changes.
Marcelo feels the process tends to be slower because the printer only uses a portion of the printhead to maintain a consistent focal length. You also can't print on surfaces with angles, since any change in focal length results in blurry images. Finally, most desktop flatbeds can only print on one object at a time."
Scenario Based
Depending on a print provider's cylindrical printing needs and aspirations, as well as budget, the choice between a dedicated press or flatbed with rotary option might be obvious.
"Somebusinesses may find that adapting one of their existing flatbeds to have some cylindrical printing capability may be something that works for them in the short term when they are first exploring the possibilities of DTO cylindrical printing," suggests Makrinos.
Rangel says customers often prefer the versatility of a desktop UVprinterwith a rotary option due to the range of objects that can be printed on, noting that its flexibility is valuableforbusinessesthatserve
"These printers are also ideal for larger cylinders with varying depths and profiles. Ifyou're doing high-volume work, a dedicated cylindrical printer is definitely the way to go," states Marcelo.
Learning Curves
When moving from an analog process to digital there is a learning curve.
Edwards admits that learning how to utilize the equipment to get the best results on a specific product type can take some time. "There are image design complexities, for example. Some designs are more achievable with a digital system and some less. Since this is a process color system, you need to ensure that the system is correctly profiled to achieve accurate color reproduction."
Marcelo suggests print providers may go through several test runs and waste parts until the correct measurements are determined. "But once parameters are established for a specific cylinder, you can save that configuration and use it again in the future."
Specific to dedicated units, Marcelo admits it's hard togeneralize the learning 2.LSINC produces the PeriOne, PeriQ360, and Perivallo360m,whichareallcapableofprinting oncylindricalandtaperedmedia.
curve because there are so many differentprintingtechnologies outthere. "With a flatbed printer, the learning curve is relatively simple. You're just adjusting the artwork size and placement, so there's no need to conduct image separations."
One area that requires some knowledge is design. Rangel explains that setting up artwork for a curved surface requires a different approach than designing for a flat print, as users must consider distortion and alignment.
During art development the same traditional techniques of art stretching apply as required for offset and screen printing. "If one wants a logo to look like a circle from the front, the art must be stretched from side to side so one's eyes perceive it as a circle from the viewer's perspective. Simple online tutorials can have an artist fully functional upon completion," explains Bullington.
Riley also feels that some people struggle a bit upfront with visualizing
the orientation and placement of art on objects when moving between flat and rotary. "With our Catalyst printers, the rotary is simply an extension of the flatbed so the actual process of embellishing a cylindrical object is exactly the same as printing a flat object. We can also use the same repeatable templates, making it easier for operators to print two, three, or four objects on the rotary at the same time, or call up prior jobs and easily repeat them."
Rangel says the printing process itself is user friendly given that Mutoh provides detailed instructional videos and implements features in its RIP software, VerteLith, that allow users to output jobs without the need to make many changes on the fly.
When working with a kebab option on the Mimaki UJF Series printers, Gonzalez feels that the learning curve is quite short. Mimaki authorized distributors offer training, and there's a ten
minute video available from Mimaki on installation of the kebab option.
"Understanding the mechanics and the technical applications of the cylindrical printer are the key to shortening the learning curve," states Perrelli.
IDS' technical team is dedicated to installing and training customers as well as providing continuous support for its solutions to minimize the learning curve and ensure a smooth and efficient process.
Cylindrical Focus
The potential of digital DTO cylindrical printing is notable. From cans to glassware, these objects are decorated quickly with the added bonus of customization capabilities. For high volumes and odd shapes, a dedicated press has advantages if the economics support it. If you're looking to add versatility and print to a variety of objects-cylindrical or not-a flatbed press may be the way to go. /PM
Corrugated Package Printing Grows with Inkjet
by Melissa Donovan
dvancements in printhead technology continue to change the game in terms of how and when inkjet printing is used for corrugated packaging. The newrugated plants money and time.
Past to Present
In the past, inkjet was not able to provide the quality, reliability, or speed that corrugated package printing required. Today, we are well on our way with digital hardware meeting analog technology in all three categories.
According to Kristen Minlschmidt, product marketing manager, HP Inc., when digital printing entered into corrugated production in the early 2010s with multi-pass inkjet technologies it enabled high print quality, but this was at the expense of production speed.
Nevertheless, the attraction of digital was there. "Early users of the technology were quick to migrate low-volume, high-value applications where even a limited production speed could generate returns," explains Minlschmidt.
Above: Xaar's Ultra High Viscosity Technology results in more vibrant and opaqueprints.
Throughout the late 2010s, engineers worked hard to “significantly improve production speeds while retaining high quality by using single-pass inkjet. This improvement reduced production costs and allowed converters to economically produce higher volume orders. As the technology continues to rapidly advance, inkjet is now a transformative solution that’s swiftly changing the dynamics of box production,” admits Minlschmidt.
Jochen Sproll, strategy and business development manager, Koenig & Bauer Durst GmbH, agrees, stating that with the water-based inks and high-resolution printheads found in printers like Koenig & Bauer Durst’s Delta SPC 130, quality, reliability, and efficiency standards are met.
“Historically, inkjet printing faced challenges in meeting the quality, reliability, and speed demands of corrugated package printing. However, advancements over the past decade have significantly bridged this gap,” adds Bill Myers, marketing manager, Domino North America.
Neil Cook, business development manager, Xaar plc., believes “inkjet technology can meet and even surpass analog printing in many cases, providing the added benefits of digital flexibility, customization, and sustainability.”
Independent, peer-reviewed research from Swansea University’s Welsh Centre for Printing and Coating back up Cook’s statement. Its study validated the impact of Xaar’s Ultra High Viscosity Technology with its Aquinox printhead, which
can jet fluids of up to 1,000 centipoises at ambient temperature.
The study reported up to a 67 percent increase in color density on coated white corrugated substrates, achieving more vibrant prints without additional processing. The high-viscosity inks used also matched the intensity of conventional inks but required less volume, needing up to 50 percent less ink than standard viscosity inks on both primed and unprimed media. This translates into faster drying times and lower energy consumption.
Corrugated Board Challenges
Corrugated board presents unique challenges, for example printhead nozzles may get blocked from dust. Luckily, inkjet manufacturers are eliminating or at least minimizing these issues.
First, we must understand how crucial it is that the printer is placed in a clean and controlled environment. “The clean room not only protects the print engine from corrugated dust, it also creates a stable environment related to temperature and humidity,” shares Chuck Slingerland, VP, Barberan Corrugated NA.
Automated cleaning and capping systems are key to preventing or minimizing printhead nozzle blockages from cardboard dust. The Domino X630i includes the i-Tech CleanCap, an automated cleaning and capping system that reduces maintenance needs and ensures consistent print quality.
Koenig & Bauer Durst addresses them with a forgiving feeder, preprint sheet cleaning, and tight control of board quality throughout production.
The physical nature of corrugated board is unwieldy and complicated. “Corrugated substrates vary in texture, thickness, and absorbency, which can directly impact print quality and consistency. Ink absorption into the substrate was always a challenge, leading to duller colors and increased ink usage,” explains Cook. Xaar’s Ultra High Viscosity Technology addresses this as the pigment in high-viscosity fluids sits on the surface rather than being lost to absorption, resulting in more vibrant and opaque prints.
Minlschmidt also suggests variability in board/paper thickness, warp, surface texture, and moisture content as challenges that can complicate achieving consistent ink application and image quality when printing to corrugated board.
Xaar’s TF Technology also ensures continuous ink recirculation, reducing nozzle blockages from cardboard dust and maintaining reliability in high-production environments.
“Dust, board warp, and inconsistent stacking are challenges,” lists Sproll.
HP technology is designed with these challenges in mind. Printhead designs, featuring improved nozzle protection and ink recirculation systems, minimize the impact of dust and ensure reliable ink delivery. Board handling capabilities and precise tension control accommodate a range of board/paper thicknesses and surface variations.
“In addition, cardboard is full of air and has uneven printing surfaces,” notes Philip Chu, product manager - UV printers, Roland DGA Corporation.
Printheads on the Case
Printhead improvements advance inkjet in corrugated package printing.
Historically, first generation, singlepass printheads were limited, operating at 360 dpi with large droplet sizes in 1. HP printhead designs feature improved nozzle protection and ink recirculation systems. 2. Samples from the Domino X630i digital aqueous inkjet corrugated press.
the range of 12 to 13 picoliters, according to Slingerland. “In contrast, second generation printhead technology offers significantly higher resolution and much finer droplet sizes, enabling sharper detail and more lithographiclike image reproduction.”
A printhead efficiently jetting fluids is a key component to inkjet reaching analog speeds, precision, and quality. “Xaar’s printhead technology enables the jetting of much higher viscosity fluids than ever before. This innovation redefines what’s possible for users, unlocking new opportunities in print, and setting a new standard for the industry,” explains Cook.
“Advanced piezoelectric printheads with recirculation ensure uptime, precision, and long-term stability—even in 24/7 operations. They’re key to minimizing
clogging and supporting high-speed, high-resolution printing,” says Sproll.
The newest iterations of HP Thermal Inkjet printheads offer high nozzle density, scalability, and reliability, which enable high-speed, high-resolution printing. HP’s latest generation industrial printhead technology on the PageWide T1195i and T700i Presses offer improved reliability that benefits system productivity and reduces operating costs all around.
Printheads and precision go hand in hand. “Advancements in printhead technology are pivotal for inkjet printing in corrugated packaging. The Domino X630i utilizes i-Tech StitchLink technology, which ensures precise alignment of printheads, delivering seamless and high-quality prints across the substrate.
This precision enhances image quality and reduces setup times,” states Myers.
Further Advancement
Besides printheads, other components of the corrugated printing process advance inkjet.
Ink updates are one. “Water-based white ink—including Koenig & Bauer Durst digital water-based white for corrugated substrates in primary food packaging, as well as efficient drying systems and workflow automation are driving performance, flexibility, and sustainability,” says Sproll.
“The Domino AQ95 aqueous ink set enables printing on both coated and uncoated corrugated materials without the need for pretreatment, expanding application possibilities,” says Myers.
Cook cites Nazdar's HighV Aqua Coro high-viscosity water-based ink, which minimizes absorption into the board to deliver superior color vibrancy and reduce overall ink usage. "Since less ink soaks into the substrate, graphics printed in a single pass appear significantly more striking compared to those using standard viscosity inks."
"These benefits are relevant for corrugated packaging, where high-viscosity inks enable a broader color gamut without the need for coating or primer, reducing costs and resource usage while improving efficiency. Additionally, by reducing water content in inks, drying energy requirements are lowered. This makes the process more efficient and environmentally sustainable," continues Cook.
Anotherimportantcomponentis fluid management systems from companies like Megnajet. "These are also important for advancing inkjet for corrugated printingbymaintainingoptimalinkconditions throughoutlongprintruns,ensuringconsistencyandreliability," says Cook.
Inspection systems help to eliminate registration errors. Barberan S.A. employs its proprietary MasterVision camera inspection system which not only aligns printheads automatically, but also enables real-time monitoring of printqualitytoensureconsistentoutput, notesSlingerland.
Workflow plays a role. "HP One Package software is designed to leverage digital efficiency and flexibility, while effectively connecting an HP PageWide Press with existing factory systems. With the HP One Package software, convertershave a wide choice of proven HP and partner solutions to
support every stage of the digital print workflow," explains Minlschmidt.
Automation
Driving efficiency across the entire corrugated production configuration is automation, whether it's on the back or front end of the process.
"To ensure a smooth transition to digital printing for corrugated production, converters place a premium on preserving operational efficiency and minimizing costly disruptions to established workflows. Automation emerges as a strong enabler of this goal, driving efficiency gains through streamlined processes, reducing manual interventions, and improving consistency," notes Minlschmidt.
Automation is pivotal. ''Automation directly boosts efficiency and productivity. Thecorrugated industryisn't looking for gimmicks. Converters demand performance, cost efficiency, and consistent quality. A smooth and reliable printing process is essential, but it's just one link in the packaging supply chain that helps brand owners attract attention and win over their consumers," sharesSproll.
''Automation in media handling and finishing streamlines production, reduces manual intervention, and enhances efficiency," adds Myers.
Chu agrees. "Increased automation as well as other front- and back-end improvements translate to increased speed and efficiency, which means faster turnaround times. Proper material treatment andhandling makes everything faster;'
Into Future Use
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Inkjet is changing how corrugated board is printed. Compared to a decade ago, speed and quality have matured considerably thanks to advancements in printheads,inks,andautomationcomponents.
We discuss this topic in more detail inourupcoming webinar,takingplacein June. Visit industrialprintmagazine.com to register today. 1PM
