Conventional wisdom dictates that there are limitations to each of the individual printing processes. Web is geared for long runs on only a few substrates; Sheetfed is only economical between 1000 and 50,000 impressions, or when the substrate can’t work in a web machine; Flexo is a packaging process; Screen printing is limited to very short runs on ridged substrates.
Flatbed machines are an extension of digital printers, but their limitations have been the lack of economies of scale on longer print runs and the inability to print on more difficult substrates. While the first issue remains the same, UV flatbed printers have virtually eliminated the second issue. These innovative machines can print at a rate of 4000 sq. ft/hr and can get you up to 1000dpi on the sheet. However, the best part of the technology is that it’s not limited to sheets. UV flatbeds can print on certain kinds of vinyl, PVC, styrene, lexan, foam, corrugates board, card stock, metal, polyethylene, polyester and acrylic surfaces. Notice the word “certain” in the previous sentence. That’s because while this technology has made great leaps and bounds, there are still only a limited number of those types of materials that are approved for use in UV flatbed machines.
What might be more amazing is that this process uses the same ink for all the substrates mentioned. Unlike screen and many other types of printers who change their ink types depending on the substrate, the UV flatbed process uses the same inks for all substrates. While this helps explain why only a limited number of the substrates work with the process, the fact that it all uses the same ink means there is no wash-up or changeover time lost and ordering inks is a no-brainer.
Production range, however, is still limited. The optimum range of printed pieces for this process is 25 – 1000 impressions. This technology seems to work best in a screen shop as a complementary piece of equipment, and it works with the printer’s current product offering. Not only would the machine be able to contribute its own business, it would work as a one-off proofing system, mimicking the actual output of screen press on the same substrate.
The equipment is not abundantly expensive, nor is it cheap. A basic 6-color inking system sells for under $200,000.
Ah yes, but what about training? Most retailers of this technology feel that individuals with good basic computer skills can master the inkjet software in a matter of weeks with little-to-no additional training. If you want to invest in training (always a good idea in my mind), one week or less of onsite training should be sufficient.
So is this technology the last hurdle that has to be cleared in order for digital to become THE printing process? Obviously there are still many issues that have to be addressed. The run length is still the one factor that keeps people from using the process for a huge majority of print jobs, but the increasing ability to print on a multitude of surfaces means that the factors that draw people away from digital processes are being diminished. It may be years away, but it does look like digital will be the technology used on the bulk of print jobs in the future, and the UV flatbed is just one innovation that is helping to move business in that direction.