.RIAL 9PRINT
INDUSTRIALPRINTMAGAZINE.COM
Volume 12,Number 5
DIGITAL DECORATIVE PRINTING
The possibilities are endless when it comes to digital decorative printing. While flooring manufacturers experienced early success with digital printing, other segments of decor are slowly beginning to understand the advantage of the technology.
Our cover story, Trailblazing Technology, looks at how furniture manufacturers recognize the flexibility and personalization possibilities digital presents. As individualized requests and bespoke designs increase, it's no surprise that digital printers-whether single- or multi-pass-are leveraged to decorate surfaces that go on to be used in bar tops, chairs, tables, and more.
Switching to the direct to object portion of this edition, Overcoming Obstacles addresses printing directly to items with handles-from coffee mugs to water bottles and buckets. These are increasingly popular as brand owners look to personalize using a cost-efficient, quality method.
Data and Reporting discusses analytical tools found in workflow solutions designed for corrugated printers and box plants implementing digital options. Taking advantage of these features leads to an efficient production floor.
TAPPI recognizes the importance of digital print technology for corrugated at its annual gatherings. This year CorrExpo takes place in Savannah, GA from October 20 to 22. Learn what to expect in a preview of the event on page 6.
This issue also includes a spotlight on a kitchen manufacturer leveraging single-pass digital printing in house, an article on post-processing for three-dimensional (3D) printing, and a chart listing 3D metal printers.
Cheers
Melissa Donovan, Editor
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BUILDING CORRUGATED
CorrExpo
2025 Preview
From October 20 to 22, 2025 members of the corrugated packaging industry convene in Savannah, GA at the Savannah Convention Center for CorrExpo 2025. Spread throughout three days, presentations, a busy show floor, and after-hours networking opportunities are available to attendees.
Hosted by TAPPI, the leading association for the worldwide pulp, paper, packaging, tissue, and converting industries, CorrExpo is known for its timely discussions on what’s new in corrugated. To that extent, it holds the What’s New Program on Tuesday and Wednesday during the event. Participating exhibitors step into the limelight for seven minute power presentations focused on their latest innovations.
1
Of note, AI in Corrugated from Michael Ochi of Amtech Software, Digitally Transform Corrugated Packaging Production with Kerry Sanders from EFI, Infrared Drying for Corrugators with Jack Karas from Oxytech Systems Inc., and Putting the Pieces Together: Streamlining Corrugated Workflows with HP One Package with Kristen Minlschmidt from HP Inc.
On the Floor
Over 130 exhibitors are slated to showcase their products and services in the convention hall in GA. Those vendors part of the industrial printing space share their plans for the show here.
A.G. Stacker , booth 407, encourages attendees to learn about the eBREAK, eZFa, and eXT systems with its DUO digital twin technology. Explore digital shadow tech on the eXT and get hands on with collaborative tools like GO AG and SIMCORRA—built to boost insight, communication, and
structure on your production floor. From bundle breakers to load formers, A.G. delivers future-focused innovation across the line. INFO# 155
Advantive , booth 539, demonstrates Kiwiplan, its integrated ERP and MES solution, which empowers sheet and box plants to display and specialty packaging manufacturers with digital capabilities. Key features include maximizing throughput and daily square footage with 24/7 automated tracking and scheduling, minimizing delays and increasing efficiency by integrating shipping and production planning, improving on-time delivery and reducing waste and work in progress with advanced automation, and maximizing labor efficiencies and visibility with streamlined and standardized enterprise-wide processes. INFO# 156
1. Baumer hhs, booth 719, invites attendees to see the latest in gluing and glue verification technology with its CorrBox EVO. 2. Kongsberg demonstrates digital cutting solutions for corrugated converters in booth 727.
digital printers, they deliver crisp detail and long-lasting durability for corrugated board and display media; INXhrc natural-based inks, these inks have replaced petrochemical-based ingredients with renewable raw materials inks for a high-performance, sustainable solution that reduces your carbon footprint; and INXJet AC9087 Primer, which ensures sharper images and consistent aqueous production to unlock greater flexibility across corrugated applications. INFO# 165
Kento Digital Printing, booth 725, shares its new, 66-inch inline rotary die cutter option, developed to meet North American market standards. Kento Hybrid is a modular and scalable solution designed exclusively for corrugated, it integrates up to three flexographic units, single-pass digital inkjet, and an inline rotary die cutter into one seamless line. Don't miss the opportunity to
see how hybrid printing bridges the gap between analog and digital, transforming your plant's efficiency and competitiveness, opening the door to new clients and markets. INFO# 166
Kongsberg Precision Cutting Systems (PCS), booth 727, highlights how itsdigitalcuttingsolutionsforcorrugated converters, including its Kongsberg Ultimate, help solve everyday business challenges. It focuses on increasing productivity with Kongsberg PCS advanced automation options including the Smart Media Handler and Feeder & Stacker, which can be integrated with its cutting systems and tailored for differing business needs. INFO# 167
Signode, booth 419, invites attendees to discover how itproduces packaging solutions for the corrugated industry. Providing strapping and wrapping equipment as well as strap and stretch film, join the team in the booth to discuss your packaging challenges and how Signode can find a unique solution. INFO# 168
SUN Automation Group, booth 101, showcases innovations that drive efficiency, precision, and performance in
heavy-duty design, accuracy, and reliability in high-volume production. SUNalso presents Helios, its OEM-agnostic IloT solution built by experts to provide real-time machine insights that reduce downtime, optimize productivity, and cut waste. In addition, SUN is proud to feature leading solutions from its global partnersKolbus,LMC,PARA,andVersorexpanding capabilities in short-run boxmaking, finishing, material handling, and sheet feeding. INFO# 169
Valeo Melton, booth 620, presents the latest innovations in next-generation packaging technology. The company offers cold glue systems for flexo-folder-gluers, folder-gluers, and specialty folder-gluers, it also offers a range of hot melt dispensing equipment purpose-built for applications such as semi-automatic general and universal tapers. Hot melt systems can be tailored to support custom box requirements and hot/cold assist applications. INFO# 170
WSA USA, booth 324, brings a full team to the show and would love to talk about its facility automation capabilities and advancements with attendees. Are you looking to move the needle in your factory automation capabilities and advancements? Contact WSA today to start the conversation around your needs and the company's process to see how it can be a great partner to you as well. INFO# 171
corrugated converting. Attendees ex- Make
Plans
ploresolutions such as the SUN625HD TAPPI expects more than 1,500 corRotary Die Cutter, celebrated for its rugated industry professionals to join
3. BAHMULLER,booth121,presentsafullyautomated stack-to-stack packaging solution that tackles labor shortages and rising quality demands. 4. INX promotes productsthat help corrugated printersachieve resultstodayinbooth706. CorrExpo 2025.
Visit tappi.org to learn more and make your plans for attending. Industrial Print magazine is a proud media sponsor of the event. /PM
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116 Meltio MeltioM450 meltio3d.com MeltioM600
117 Nikon LasermeisterLM300A ngpd.nikon.com/en LasermeisterLM102APro
118 NikonSLMSolutions SLM2802.0 nikon-slm-solutions.com SLM280PS SLM500 NXGXII600 NXG600E
119 PrimaAdditivebySodick IANUSCell primaadditive.com
lASERDYNE811
lASERDYNE795
LaserNext2141
PrintSharp150 PrintGreen150 PrintGenius150 PrintSharp300
PrintGenius300
PrintBrilliance300 PrintGenius400
PrintGenius400XL
120 Rapidia Confluxl rapidia.com
121 Sciaky,Inc. EBAM-53 sciaky.com EBAM-110 EBAM-360
122 sharebotsrl metalONE sharebot.us
123 TRUMPF TruPrint1000BasicEdition trumpf.com TruPrintlOOO
TruPrint2000 TruPrint3000
TruPrint5000-200"C
TruPrint5000-500"C
TruPrint5000-Green
124 UltiMaker UltiMakerMethodX ultimaker.com UltiMakerMethodXCF UltiMakerFactor4
UltiMakerS6
UltiMakerS8
125 Velo3D Sapphire velo3d.com SapphirelMZ SapphireXC SapphireXClMZ
126 XactMetal XM200G xactmetal.com XM300G
127 XJet3D Carmel1400MMetalSystem xjetld.com Carmel5000XMetalSystem
SURFACE FINISHING
Post-Processing Techniques for 3D Printed Parts
by Cassandra Balentine
Many three-dimensional (3D) printed objects require post processing before they are considered complete. Surface finishing is often utilized for 3D printed products in aerospace, medical, and automotive industries that yield metal or polymer parts, these are able to be finished into smooth, polished pieces.
“To achieve the desired final finish for your printed parts, consider three main factors that are often ignored by manufacturers—how to post process the parts after the build, how to deal with the high surface roughness of the printed parts compared to machined or casted parts, and how to specify the surface requirements on the part print,” explains Andrew Garganese, marketing, Bel Air Finishing Supply Corporation.
The type of post-processing finishing varies depending on the desired outcome or purpose of the part. “Will it be a visual prototype? Is it a part that is not visible but needs to meet certain criteria for mechanical properties? Is it a functional end use product?” asks Mike Schorr, GM, DyeMansion North America.
Each industry has different needs and Schorr points out that for prototyping there usually won’t be much attention paid to the surface finish beyond standard depowdering, mechanical surfacing, and possible color. “When you move towards end use consumer-grade products, then generally a specific color is needed and the requirements for the surface change.”
Schorr feels that it’s at this point when surfaces become more critical and appealing to the end user.
Varying Techniques
Post processing is an essential step to improve the appearance and performance of printed parts. It can remove excess material, smooth out rough surfaces, and enhance the mechanical properties of the parts.
Garganese stresses that post-processing methods vary depending on the part type and geometry, so you need to “plan ahead and choose the most suitable method for your design.”
A variety of post-processing surface finishing techniques are utilized today, including bead blasting, shot peening, media tumbling, polishing, sanding, heat treatments, plate treatments, and vapor smoothing.
Bead Blasting
…plan ahead and choose the most suitable method for your design.
— Andrew Garganese, marketing, Bel Air Finishing Supply Corporation
To access challenging-to-reach areas, a blog post by Snapmaker US, Comprehensive Guide to 3D Printed Parts Surface Finishing, says bead blasting is the ideal solution. “Through this procedure, you can utilize a spray gun to shoot finely reground thermoplastics onto the surface in order to remove any imperfections and produce a smooth finish—much like sanding does but far quicker. Not only will it improve your end product’s aesthetic appearance with its matte finish, but it also acts as an efficient means of prepping materials before adding coating so that they adhere correctly.”
In order to avoid dents in the material, Snapmaker suggests using bead blasting and starting out on a low pressure setting and slowly increasing if required. "Too highofapressureorlingeringononearea for too long canobliterate ample amounts ofthepartyouare workingwith:'
ShotPeening
Shotpeeningworkssimilartobeadblasting, yet ithasanalternatepurpose. Snapmaker's blog says that instead of eliminating any undesirable imperfections fromthesurface, thistechniqueprimarily serves to enhance the part's strength and durability. With shot peening, high-pressure air blastsminusculemetal or plastic beads at the object's exterior in much the same way as with bead blasting. These particles then make shallow pits on its face under, in which compression strains form when they overlap. Therefore, shot peening increases the component's ability to resist wear and tear while also increasing longevity.
"The compressive stress, which reduces the size of an object, replaces tension in the item that would otherwise expandits length. The compression makes the surface more resilient and better abletodefenditselfagainstfatigue, wear
1.& 3. DyeMansion offers a fully modular print-toproduct workflow, which includes cleaning, media blasting, vapor smoothing, and dyeing technology. 2. MFI offers many types of tumbling equipment for use in medical, aerospace, automotive, dental, and defenseindustries.
and tear, cracking, and cavitation erosion," shares the Snapmaker blog.
MechanicalSurfacing
Mechanical surfacing is a media blasting or shot peening process, where the parts are generally placed in a process chamber that tumbles the parts while exposing them to blasting media. "The blasting media uniformly smoothes the surface without removing critical geometries or dimensions. The result is a smooth, yet matte surface with pleasing haptics," explains Schorr.
Media Tumbling
Tumbling works across all manufacturing industries, says Cole Mathisen, sales and marketing manager, Mass Finishing, Inc. (MFI). There are many types of tumbling equipment including vibratory, centrifugal disc, drag or spindle, and centrifugal barrel.
MFI's centrifugal barrel tumbling machinesusefourbarrelsorworkchambers that are mounted on a drum and rotate in a planetaryor ferris wheel likepattern. "Thisone-to-onebarrel toturret ratiocreates a wave inside the barrel. The parts are tumbled with various types of media including ceramicandplastic shapesthat haveabrasivematerial bakedin. The rubbing of media against the parts creates a perfect isotropic-even in all directionsfinish. This is superior to sanding or buffing that can leave directional patterns on parts," saysMathisen.
MFI's HZ Series of nine sizes of centrifugal barrel tumblers are used in medical, aerospace, automotive, dental, and defense industries along with many others including jewelry. "Depending on the size and geometry of the part, we have smaller and larger machines and different media sizes to affect different part features," notes Mathisen.
With rough parts, MFI typically suggests a highly abrasive ceramic media for 45 to 90 minutes to smooth out the rough surface and get the finish down to around 45 microinch Ra. From there it uses a finer abrasive type media for 30 to 60 minutes to blend and smooth the surface further to a 15 to 25 microinch Ra. Then it will use a polishing media like porcelain or MFI's treated corn cob to get the parts to a mirror or sub 8 Ra finish.
Sanding
In a Formlabs article, Guide to PostProcessing and Finishing SLA Resin 3D Prints, the company says sanding 3D printed parts is often the best method for smoothing edges, removing blemishes, and getting rid of any leftover support marks.
"Hand sanding is most effective on simple shapes, but it can be hard or nearly impossible to sand complex objects with deep crevices and internal supports. Media blasting or polishing might be more effective solutions in these cases," notes the post.
Heat Treatments
3D printed objects may also undergo one of several various types of heat treatments as part of the finishing process. Surface Treatment Experts offers the Guide to Surface Finishing for 3D PrintedParts on its website, which details how heat treatment works.
The article points out that heat treatments strengthen a material by reducing tensile pressure. It evens out the high and low stress areas of an object, helping to prevent failures. You might also use heat treatment to increase density or help form the item into the final desired shape.
Plating
Electroplating transfers metal atoms from one metal to another when they are in a solution and have electricity
pass through them. When you choose this method for coating 3D printed objects, you will enjoy multiple advantages compared to other means of finishing the project, offers Surface Treatment Experts' blog post.
Vapor Smoothing
Schorr explains that vapor smoothing uses controlled vapor exposure to smooth outer layers of 3D printed parts by slightly melting the surface, closing pores, and reducing roughness. Parts that go through a vapor smoothing process usually need to be suspended in a process basket or chamber so that the entire part can be exposed to the vapor and to ensure an even, homogeneous surface finish. The result is a fully sealed part that has a smooth, shiny surface.
"Medical industries generally will tum towards vapor smoothing as a key asset to enable a sealed, washable, and more biocompatible surface," says Schorr.
Aerospace and other defense customers may use vapor smoothing to enable watertight and sealed parts that can withstand the elements. "Mechanical surfacing on the other hand creates a finish that's similar to some traditionally finished parts," notes Schorr.
Important Step
Post processing is an important step in 3D printing, as it affects the function and appearance of the printed parts, stresses Garganese.
Different post-processing methods suit various parts, depending on their shape, size, material, and surface requirements. Before choosing a postprocessing method, one should consider the following factors-the function and aesthetic needs of the part; the compatibility of the post-processing method with the existing manufacturing systems; the scalability of the post-processing method with the production volume and part diversity; and the surface characteristics of the part, both exterior and interior; and how they vary with the printer technology and build parameters.
Some common mistakes to avoid when designing 3D printed parts are replacing an existing part with a 3D printed part without considering the surface limitations and functionality of the new part; designing 3D printed parts that have complex or inaccessible surfaces that are hard to post process; or using a printer technology that does not match the surface requirements of the part.
Final Step
US us.snapmaker.com
150 Surface Treatment Experts sharrettsolatina.com
Many 3D printedobjectsbenefitfrompost processing, especially in instances that go beyond prototyping and require polished final products. The technique used varies based on the part's shape, size, material, and surface requirements. /PM
DATAANDREPORTING
Driving Efficient Production Floors
by Melissa Donovan
Corrugated printers and box plants that utilize digital printing in house benefit from the software that comes with it, particularly the data analytics and reporting pulled on a daily basis. Taking advantage of this information can help grow a business and maintain an efficient production floor.
Technology in Use
There are many benefits to using automation software in digital corrugated board printing environments. One of which is the various data and reporting features that many workflows come equipped with, or if not built into the program, can integrate with a third-party solution.
Corrugated sheet plants and box plants rely on data and reporting features found in their current software solutions to drive smarter and faster decision making on the plant floor, according to Craig Tait, chief product officer, eProductivity Software (ePS).
Matt Crawford, president/CEO, Onyx Graphics, Inc., says reporting
Datahelpsyouunderstandwhichjobs areprofitable,whichmachinesare underperforming,andwheretofocus improvements.
-MattCrawford,president/CEO,OnyxGraphics, Inc.
maintain consistent quality, schedule smarter, and measure performance, lists Crawford.
"Business owners can clearly see how printers and staff perform and where improvements can
"They're using real-time production data to monitor quality, tools also enable box plants and corrugated printers to run track waste, optimize ink consumption, and ensure jobs run smarter and faster-in addition to becoming more profitable. on time and within spec.Manyplantsalsointegrateconverting Modernprintsoftwarewithdataandreportingfeaturesallow data with upstream scheduling and ERP systems to align con- users to trackjobs in real time, monitorink and material usage, verting production with order management and capacity planning. This helps teams proactively identify bottlenecks, adjust to last-minute changes, and improve overall equipment effectiveness," explains Tait.
1. ePS plays a critical role in ensuringtheentireproductionworkflow-from order entry to shipping-runsefficiently.
be made. Having data from past jobs makes it easier to plan production days and avoid last-minute delays," continues Crawford.
Benefits to Consider
Integrated workflows reduce costs and increase uptime. The tools integrated throughout the system offer these two major advantages and more depending on the part of the process they are involved with. Data and reporting features offer significant benefits.
Automation features in software offer real-world business advantages. ''Automation means less time setting up files, more time printing, and fewer operator mistakes," saysCrawford.
Utilizing data and reporting features is essential to making better decisions
understand which jobs are profitable, which machines are underperforming, and where to focus improvements," sharesCrawford.
"The reality is that many plants still operate in silos with a patchwork of legacy systems. If data and reporting tools can work with what's already in place and deliver immediate insights without a steep learning curve, adoption increases dramatically," admits Tait.
Vendors as well as industry leaders need to enhance software technology with a focus on interoperability, ease of integration, and user-friendly dashboards, lists Tait.
Crawford agrees. To help more companies take advantage of software solutions like these, systems need to be designed to easily connect to other systems, be simple to use, and work well with hardware. "Clean, easyto-use dashboards help teams see what matters most without needing technical
to work with printers, finishers, and cutters right out of the box, adoption is faster and smoother."
Education is also important. This includes success stories that "showcase tangible return on investment (ROI) from automation and reporting, which can help justify investment internally," acknowledges Tait.
"Data and reporting features offer training and when software is designed better visibility across the production process, enabling faster troubleshooting and reducing downtime. They help identify trends in converting defects, enable consistent repeatability and quality control, and provide actionable insights for ongoing improvement. From a business perspective, they support more accurate job costing, drive down waste, and enhance customer satisfaction by ensuring print consistency and delivery performance," explains Tait.
Adoption Push
While most production facilities have
about print operations. "Data helps you implemented software solutions that in-
2. ePS tools empower converters to reduce costs, improve uptime, and deliver quality output at speed and scale with data and analytics.
Showing ROI is how shops will truly understand the benefits, and then adopt the software. "Many shops save money and increase output by reducing errors and waste-real numbers help show the value," saysCrawford.
elude data and reporting features, many Insightful Operation are not using themtofull capacity. Accel- Data and reporting features in workerating adoption in this space is a must. flow software are useful tools that provide corrugated printers and box plants with insight into their production operations. Using the information that comes from these features allows shops to run more efficiently and achieve a faster ROI. /PM
LaChance, digital product manager, Inkcups, says it remains a relatively niche segment within the broader DTO landscape. “The key for many print businesses is flexibility,” continues LaChance.
Niche Segments
Dedicated DTO printers as well as certain flatbed configurations are able to handle cylindrical DTO printing. Depending on coverage needs—full or single-sided decoration—for printing to products with handles, a dedicated solution may be necessary.
Segmentation in DTO is driven by demand for specialized, high-margin applications like custom drinkware, promotional items, and more.
Perrelli points out that print providers have options. “Some of the DTO printers we offer provide a range of versatility capable of printing on everything from cylindrical cosmetic packaging and shot
1. Apex, Desco, and Goldstar America—all of which fall under The Apex Group—offer a variety of custommade printing, decorating, marking, handling, and automation equipment for over 30 different market segments including medical, pharmaceutical, automotive, sporting good, household, and industrial.
glasses to larger items like beer growlers. Others, like our dedicated handled object printer, were designed to serve a market segment that had previously been overlooked until we launched the machine last year.”
Before the release of dedicated solutions like IDS’ RevHDL, companies looking to UV print on handled objects typically relied on flatbed printers, which only allowed for a small print area—something many users found limiting. “The introduction of the RevHDL expands the printable area around the mug, unlocking creative possibilities that weren’t achievable before,” explains Perrelli.
“In our experience, most customers look to increase their versatility at the same time as prioritizing speed and lower volume orders. This is where modularity comes into its own with flexible, modular solutions,” notes LaChance.
James Bullington, CTO, LSINC Corporation, points out that while printing to handled items can be niche, the market is not yet oversaturated. “There are specific items that require unique solutions whether it be based on size, material, or substrate type.”
LSINC’s PeriH is a functional addition to its DTO offering that directly addresses the requests of numerous clients for the ability to digitally print directly to an object with handles. “Its ability to print on multiple types of materials makes it a versatile addition to the promotional product market,” shares Bullington.
Flatbed printers like the Mimaki USA, Inc. UJF Series print to handled items, but with limitations. “Because of the geometry, most handled objects can only be printed on one side at a time unless custom fixtures or pre/post handling are used. That said, Mimaki’s long distance (LD) print profiles are a significant advantage—allowing clean printing on surfaces with up to 4.5 millimeters of variation, which helps maintain quality even when printing near edges or contours,” says Hugo Gonzalez, senior IP segment specialist, Mimaki USA.
While handled items are popular, Gonzalez considers specifically built printers niche solutions. “In most cases, there are existing technologies that handle this need well. For example, UV direct to film (DTF) printers like the UJV300DTF-75 are ideal for curved or handled objects, applying detailed graphics with full wraparound coverage—something flatbeds and cylindrical attachments typically can’t accommodate.”
The custom tooling, drop table, and High Throw technology on Inkcups’ X5-T High Throw flatbed printer enables users to expand their application range without the need to invest in a new printer for every object type. “The X5-T can accommodate a variety of objects, including items with handles, and was developed in response to customer demand. This enables print providers to meet demand for personalization without taking up additional floor space or budget for highly specialized equipment,” adds LaChance.
William J. White, SVP, global sales and marketing, Apex Machine Company & Desco Machine Company LLC, says Apex designs custom machines for individual
customers' needs. While many have the same base and may share a lot of design commonality, White says it designs its systems to provide a turnkey solution for the unique requirement of that project. "Many times we have had customers come to us because an 'off the shelf solution doesn't accommodate their needs when needing to run parts with handles."
O&PM Europa BV's DTO solution can print to items with or without handles.
Riley feels that if anything, DTO printers are becoming less segmented and more capable. "True multifunction is a high bar when you talk about DTO because there are so many different media possibilities. It is impossible to do everything well."
Both DPI's Catalyst Nanos and CatalystAventra printers print directlytoitems with handles, however they are subject to
the physical limitations of the machine. "That is, the handle cannot pass into the linear plane of the printhead," says Riley.
The Catalyst Nanos printer has flatbed, rotary, UV DTF, and roll printing capability in the same small footprint, accomplishing what once required three or four separate machines.
Gonzalez feels that segmentation in this space is in response to increased demand for specialized output. "When there's a strong market like with custom tumblers or promotional drinkware, it makes sense for dedicated systems to exist. But the core of the industry still leans toward flexible, multi-application equipment. Printers that can adapt to multiple object types, materials, and workflows remain the most attractive option for shops that need to maximize return on investment (ROI) and floor space."
Longer Runs
A big advantage of DTO printing is that it makes it possible to print a variety of volume sizes from print runs of one to 500 without reducing cost effectiveness. '�dditionally, the ability to print a single item cost effectively means that prior to completing a job of 200 the print provider can print a test without significant cost or time impact. This is especially beneficial given the variable nature of personalized print," says LaChance.
Bullington points out that in today's web-driven marketplace, order sizes continue to shrink, meaning DTO equipment must be flexible via its tooling and changeover. "Doing so aggregates the quantities of numerous items with only the incremental tooling cost for each item:'
Dursun Acun, sales director, O&PM Europa, believes that DTO systems will
not only replace labels or silkscreen systems, but that the whole logistics around the products is more efficient. “The breakeven strongly depends on a total business case.”
White suggests that many times the breakeven point is much lower than anticipated. “Especially since the pandemic, many customers have lost faith in outsourcing and contract print houses have been extremely backordered thus our customers are looking to bring the printing in house. There are also many internal factors like the ability to avoid handling products more than once and being able to provide ‘rush’ jobs versus having to wait on the print houses.”
As with all print technologies, Riley says the longer the runs, the more cost effective the machines become on a perjob basis, as a function of turnover time, prepress, and retooling or adjustments required between jobs. “While machine cost, ink cost, maintenance, and uptime are, of course, big factors in profitability— time is an equally large consideration.”
Handled items can follow the same breakeven path through flexibility. “A quantity is difficult to assess. The PeriH’s flexibility supports items as small as a tea cup to as large as a 40oz travel tumbler. The margins on the latter are considerably different than that of a plastic camping cup,” offers Bullington.
Gonzalez feels that handled items can be quite efficient to print even on a flatbed, when set up properly. “Using a jig-based workflow, it’s possible to print 20 coffee mugs at a time. On a printer like the UJF-7151 Plus II, using an LD profile, you can decorate about half the exposed side of each mug in one pass. Depending on resolution, the entire jig takes about five to eight minutes per side, offering excellent throughput without the need for a dedicated machine.”
Perrelli finds it difficult to quantify a breakeven point as customers leverage the equipment for different purposes. “For example, we have one customer
2. & 4. Included in Inkcups’ portfolio are the Helix range of cylindrical inkjet printers and UV inkjet flatbed printers including the X5-T High Throw model. 3. The DPI Laboratory Catalyst Nanos and Catalyst Aventra flatbed printers are capable of flatbed and rotary printing, and the Nanos adds roll-based printing in a smaller footprint.
that uses the RevHDL as a means to move the drinkware product. Without thecustomizationon handledprospects, they know their customers will seek out other brands who do offer it. On the opposite end of that spectrum, we have customers who charge a premium to provide one-up custom drinkware with high-quality prints. The breakeven point for a customer like that would happen much sooner, but it doesn't make the other sales model less valuable."
Because not all decorators charge a premium for the decoration, but in some cases as a means to move product, Perrelli stresses that whether or not a item has a handle still makes the breakeven hard to quantify. "For the customers that
The key considerations for ink selection often lie more in the preparation steps and processes required to achieve dishwashable results. "While the ink certainly plays a role, the pretreatment process can varysignificantly. Forexample, a powder coated travel mug requires a different approach than a ceramic mug prior to printing," notes Perrelli.
As with most digital printer applications the choice of ink is driven as much by the printhead choice and target substrates. "The need to apply each color plane sequendo charge a premium for the decoration, tially as the media is moved 4 I think the same ROI percentage applies beneath the next color station to handled tumblers that many customers see on their non-handled, powder coated tumbler. There is a much higher inherent value of a decorated, powder coated tumbler or travel mug when compared to a pint glass or ceramic mug," suggests Perrelli.
Ink Considerations
Whether or not an item has a handle, differentprintsurfaceshavedifferentsurface energy, whichcanmakematerialsmoreor less ink receptive. "We use dyne level as a general gauge and recommend different pretreatments based upon the media type. That said-some, but not all UV inks areDTF compatible. UVDTF provides an alternative to direct print that can extend the capabilitiesof the printer andfacilitate decoration of handled items;' offers Riley.
requires proper matching of surface energy to avoid bleed and ensure adhesion. This differs from helical and interlaced printing where multiple colors could be applied in single or multiple passes," says Bullington.
When considering ink for DTO, it is important to factor in durability needs. "Items like mugs need inks that resist abrasion and moisture. LH-100 UV ink is a good choice. It's highly resistant to solvents and scratching, making it a great option for rigid handled items. That said, most UV prints are recommended for handwashing. If dishwasher resistance is important, the LH-100 of the UJF Series machine and ELH-100 ink used in the UJV300DTF-75 will offer some good performance under repeated exposure to heat and moisture,
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but again, the official recommendation is handwashing," shares Gonzales.
DTO inkjet UVprinters typically print with CMYK, white, and varnish. LaChance says there is no specific ink needed for handled items as the same formulations used in standard digital printing work perfectlyfineforhighthrow applications. "It's worth noting here that there is no universal ink for all DTO applications and the requirements and considerations are dependent on the substrate."
O&PM Europa BV D2O devices use water-based inks.
Curing Considerations
Similar to the ink used, whether or not a job requires pre- or post-curing technologies depend on the application, the substrate being decorated, and durability requirements. "Some substrates require additional help to achieve excellent adhesion, and this is where pretreatment comes in. Getting pretreatment right demands understanding of the end application and knowledge of the substrate in order to pair the right technique with the right ink and technology, so it's advisable to work with an equipment manufacturer with expertise
in pretreatment across varied applications, inks, substrates, and printing methods," offers LaChance.
Riley pointsoutthat withUV printers, there is generally no need for post-cure techniques. "We do recommend different types of primer or adhesion promoters for materials with lower surface energy such as glass, polypropylene, and some metals. These pretreatments may be applied mechanically or jetted onto the surface, depending upon the primer and the printer technology."
Perrelli stresses that the need for pre- or post-curing depends on the product. "For powder coated tumblers, a jettable primer that is applied inline on the printer is advised. For ceramic mugs, they must be flame treated offline before heading to the printer," shares Perrelli.
Apex & Desco Machine generally includes any necessary pre/post treating/ curing on the system itself.
OTO Options
There are pros and cons to utilizing a dedicated DTO object printer versus a flatbed for printing to cylindrical objects with handles and vice versa.
"The main advantage of a dedicated printer is optimization, faster setup, and alignmentforaspecificproducttype, like drinkware or bottles. But the tradeoff is flexibility. These machines typically serve a single application, making them harder to justify unless you're operating in high volumes," summarizes Gonzales.
"By contrast, flatbeds and UV DTF solutions offer more versatility across object shapes, sizes, and materials. For many
print providers-especially those in custom goods, signage, or promotional markets-investing in a flexible system provides a better long-term return and allows the shop to evolve with demand."
However, when the need is there, the biggest advantage of a dedicated DTO press for handled, cylindrical items is its ability to deliver full-color digital decoration including gradients, photos, and complex designs on a range of handled objects. "That applies to various colors-not limited by white substrates-and the ability to print on a range of materials-stainless steel, tritan, powder coat, ceramic, glass, etc. The only real disadvantage applies to a small number of customers that want to use a singular printer to print on all their drinkware," adds Perrelli. /PM
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Surface Printing for Furniture
by Melissa Donovan
the flooring market was an early adopter of digital printing technology for surface decoration. Exploring further into the decor segment, therearemanybenefitstousingdigital printing for decorative surfaces that go on tobe used in pieces of furniture like bar topsorkitchenislands.
"As demand for shorter production runs and bold, bespoke designs increases, furniture manufacturers explore new strategies
for decorative surface printing. The industry is witnessing a transformative shift from traditional gravure methods to digital inkjet printing,andmanufacturersreapthebenefits ofunprecedented flexibilityandthe abilityto create standout patterns with unmatched speed and efficiency," shares Marc Graindourze, business manager industrial inks, AgfaNV.
Above: Wood tabletop and fiooring printed digitally with Agfa printing technologies.
Accelerating Adoption
Educating furniture manufacturers about the power of digital print is a commitment, but one many vendors in this space are willing to take.
Adoption is based on market trends, according Michael Hesse, head sales, Hymmen GmbH Maschinen- und Anlagenbau. “If in the furniture industry unicolored surfaces dominate the market trend, other production technologies are more relevant. But as soon as the demand for other optics like wood or stone décor rises, digital printing comes into focus.”
“It always takes a while until a market adopts new technologies. Until now there are only niche producers for very special applications that benefit from the advantages of digital technology, but as soon as a market leader, e.g. in the kitchen industry, decides on digital printing this can become the trailblazer for this technology,” shares Hesse.
Graindourze says one way to accelerate the adoption of digital printing in furniture manufacturing is by partnering with technology providers. This can further help to lower adoption risks and unlock the full potential of digital printing in this sector.
Top Advantages
Digital print presents many opportunities to create decorative designs for surfaces used in furniture.
It offers flexibility, fast setup times, and individualization, points out Hesse.
“Less décor repetition and faster design development cycles are helping producers be ahead of competition with digital printing. No matter which décor you want to print—everything from wood over stone to artificial designs can be realized and exactly reproduced again at any time,” says Hesse.
It’s not surprising that digital inkjet technology is growing in the décor
1. DLEplus by Hymmen created this structure embossed in register 2. Both the bar top and flooring were printed digitally with Agfa printing technologies.
market. According to Graindourze, “unlike analog printing, digital processes support instant design changes and just-in-time manufacturing, catering perfectly to the trend towards ultra-bespoke interiors for residential, hospitality, and commercial spaces.”
As more furniture manufacturers realize the total cost of ownership of digital compared to analog print methods like gravure, the adoption of digital printing for decorative surfaces will grow.
Graindourze points out that analog print methods like gravure can be very efficient for large runs, but the considerable setup costs make them prohibitively expensive for shorter, smaller jobs. Coupled with the cost of bespoke cylinders for each design, lengthy design changes, and warehousing requirements for print masters, conventional analog methods prove unviable for many businesses.
“In contrast, digital printing offers highly efficient production even at small scale or variable batch lengths. With digital, every print can be unique, transition times between jobs are minimal, and customization becomes
more economically accessible. More efficient printing means manufacturers can reduce ink consumption, material usage, and lower energy bills, supporting enhanced sustainability,” notes Graindourze.
Beyond practical benefits like lower energy bills and reduced material usage, digital printing opens up endless possibilities on a creative level.
“Digital printing unlocks true creative freedom, as new patterns or textures can be implemented without new hardware or major investments, requiring only a print file to operate. Modern print engines and specialist ink sets empower manufacturers to print directly onto a staggering array of substrates, creating high-quality prints on everything from wood panels to laminated décor paper. This flexibility enables companies to deliver intricate detailing such as natural woodgrains and bespoke graphics directly onto furniture parts, eliminating the long lead times and minimum order quantities associated with analog processes,” shares Graindourze.
A derivative of the print process is digital structure printing, where the ink
is built up or embossed to provide textures and other tangible elements. This is an interesting use of digital print in the furniture industry.
Digital Lacquer Embossing (DLE) by Hymmen involves the creation of structures that are embossed in register to the décor of the surface. Hymmen’s patented technology achieves these results by printing a transparent liquid medium into a layer of structure lacquer using the Hymmen JUPITER Digital Printing Lines.
“Digital structuring supports surface performance. All features like hardness, bonding, scratch resistance, and chemical reliability of the core lacquer are remaining. Digital structuring offers even more design options for the furniture industry—structures on a unicolored surface are a highly interesting alternative to classic décor,” notes Hesse.
Hardware Notes
With a variety of hardware configurations and ink technologies out there, the best for decorative surface printing of
TECHNOLOGY SPOTLIGHT
Both Agfa and Hymmen offer digital printing technologies suitable for decorative surface printing.
Agfa stands at the forefront of digital innovation for decorative surfaces as a key ink supplier in single-pass printing on décor paper. Designed specifically for printing onto décor paper used in laminate floors, furniture, and wall panels, the company’s InterioJet multi-pass, water-based inkjet system supports consistent, high quality, and repeatable results at even the most demanding output requirements.
For direct to wood or edge band printing, Agfa’s UV-curable and LED UV inkjet inks, including the Altamira Design PID ink set, deliver industry-leading solutions. These inks minimize metamerism, maintain color constancy across varied lighting, and offer high indoor lightfastness, helping printers achieve superb color matching between panels and edge bands, which is critical for premium furniture aesthetics.
Hymmen offers a series of different line models for the JUPITER JPT-C, from a
furniture items is determined by whether the graphics look realistic and more importantly can handle wear and tear.
One thing to consider is whether a single- or multi-pass printer is effective. “The advantages of single- or multi-pass technologies depend on the needed capacity of the production line,” admits Hesse.
Certain patented technologies can work with either. Hymmen digital printing solutions for the furniture industry cover individual customers’ capacity needs and individual production processes. For example, Hymmen’s DLEplus is designed to work on its own
single plank line to handle the common production width of 1,400 millimeters (mm)up to large-scale production of 2,100 mm boards. With single-source supply by Hymmen, including intelligent handling systems for feeding and stacking of planks or boards, it is possible to realize complete production lines. The JUPITER JPT-C is capable of printing speeds anywhere from 25 to 50 meters per minute and equipped with Xaar sideshooter printhead technology with an optical resolution of more than 1,000 dpi by grayscale technology. It runs with UVcured acrylic inks.
The JUPITER Digital Printing Lines are capable of Digital Lacquer Embossing (DLE), which enables the creation of structures embossed in register to the décor of the surface being printed. The process involves printing a transparent liquid medium into a layer of structure lacquer. By modifying some of the process steps required for the conventional DLE, Hymmen’s DLEplus leads to optimized haptic effects in the case of special structure designs.
JUPITER JPT-C single-pass UV printers, but can also be combined with a multipass device.
Both single- and multi-pass technologies have respective advantages and disadvantages, agrees Graindourze, with the best one to use depending heavily on application requirements. Choosing the right approach depends on desired throughput, investment capacity, and substrate compatibility.
“In particular, multi-pass systems like Agfa’s InterioJet provide flexible configurations for short to medium runs, with high print quality and efficiency, whereas single-pass systems excel at high throughput
production. This makes them attractive for manufacturers seeking to replace or complement gravure lines in high-volume settings,” explains Graindourze.
In addition to whether to use a singleor multi-pass printer, the ink set chosen is important. Graindourze says it must be tailored for decorative applications to ensure compatibility and quality.
UV LED and water-based inks are two popular choices, though not just any standard CMYK ink will do, cautions Graindourze.
“Matching the realism of wood or stone, especially between edge bands and adjacent panels, requires precise control over ink formulation, color management, and substrate preparation. Standard CMYK inks developed for the commercial and packaging sectors simply cannot deliver the necessary hues or meet the lightfastness requirements of a high-end decorative surface,” explains Graindourze.
Graindourze points out that in the furniture sector, specialized pigments are required—like a specific red pigment instead of the standard magenta pigment— to enable printers to match the vast range of natural wood tones while avoiding color distortions caused by metamerism.
New Heights
Digital printing of decorative surfaces, particularly furniture, is in the early stages. Adopters of the technology enjoy the advantages of flexibility, fast setup times, and personalization.
“Digital printing is propelling the decorative surfaces sector toward a new era of personalization, sustainability, and design innovation. As print engines, ink formulations, and automation technologies continue to advance, digital printing will help further refine aesthetics and provide those who embrace it with a powerful competitive edge. Manufacturers that embrace digital printing today set the standard for quality and efficiency in the sector,” concludes Graindourze. IPM
