How the printing process works 19.1
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1 Printing How the printing process works 128 How to keep the print quality 130 Types of printing 132 Offset lithography: plates and paper 134 Flexography, gravure and screen printing 136
2 How the printing process works 19.1 There are 3 stages of printing Pre-press the stages needed before printing begins: Check artwork Colour separation Add quality control measures Plate or screen production Print- the actual printing process Quality of paper and card Sheet of web feed paper/card How many colours are needed Finishing-any additional processes required Special effects such as embossing, laminating, varnishing Die-cutting binding
3 How to keep the print quality 19.2 Densitometer Density is the level of darkness in a negative or positive film or print. The measurement of density is called densitometry. An instrument called a densitometer is used to measure the density. Printing quality control: Registration marks Colour bars Crop marks
4 Types of printing 19.3 Common print processes There are a lot of different printing processes to cover the vast amount of print jobs that are done. In this section we will look at the common ones.
5 TABLE OF PRINTING
6 Offset lithography: plates and paper 19.4
7 OFFSET LITHOGRAPHY The image you want to print is separated into the four colours needed to print using a computer; CMYK. Cyan, Magenta, Yellow and Black Four different negatives are made. One for each colour. A negative is placed onto an aluminium printing plate which is coated in a light sensitive chemical Ultra violet light is shone through the negative onto the printing plate. Where the ultra violet light can pass through the negative the plate the surface turns 'greasy'. This is repeated for each of the 4 negatives using a different printing plate each time. When in the printing machine the 'oily' ink will stick to the greasy area of the plates. Water is used to repel the oily ink where it is not wanted. Lithography relies on the principle that oil and water don't mix. Just like the other printing methods each colour added to the paper one at a time. Photomechanical transfer PMT, is a process where original copy is exposed to a photosensitive paper, which is then mated with a receiver paper. The two are process together, which results in the image being transferred to the receiver paper, producing a black and white print.
8 Offset lithography ctd. Lithography is the most popular form of printing at the moment. It is an expensive process to setup so is therefore only used for long production runs. Lithography is a high quality printing method capable of reproducing colour text and pictures on to paper or card. Lithography is used to print magazines, CD covers, posters and concert tickets
9 Flexography, gravure and screen printing 19.5
10 FLEXOGRAPHY Flexography is a printing process which utilizes a flexible relief plate that can be adhered to a printing cylinder. It is basically an updated version of letterpress. It much more versatile than letterpress in that it can be used for printing on almost any type of substrate including plastic, metallic films, cellophane, and paper. It is widely used for printing on the non-porous substrates required for various types of food packaging. It is also well suited for printing large areas of solid colour.
11 SCREEN PRINTING Screen printing uses a stencil through which ink is forced. The holes in the stencil are the same shape as the image to be printed As with the other printing methods each of the four colours (CMYK) is added seperately. The stencil can be made of different materials, eg paper, thin card or special photographic materials. The stencil is held in place by a fine nylon mesh.
12 SCREEN PRINTING Screen printing is limited to simple shapes. Screen printing can be used to print on rough or uneven surfaces...e.g. T-Shirts, glass bottles and PVC signs It is used for products that will not fit through a printing press Think about this! Screen printing is one of the few commercial printing processes that can be replicated in schools. Perhaps you could print some designs on to tee shirts to make some money.
13 GRAVURE Gravure is a high speed rotary process. Unlike letterpress, the print surface is lower than the non-printing surface. Ink fills the gaps in the printing plate. Paper is pressed against the plate by an impression cylinder. Unlike Lithography the print plate is made of copper which is more durable than aluminium, however, more expensive to make. As with all the other processes each of the four colours (CMYK) are added separately. Gravure is expensive to set up so is therefore only used for long print runs of over about half a million copies Gravure is used for very high quality printing. Gravure is used to print high quality magazines, stamps and fine art prints.
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