Printing 101

It's back-to-school time folks, so we compiled a reference list of printing methods and how they're most effectively used. Think of it as a refresher course, promoting more affirmative head nods when we say, "plate technology" or "movable type." And be warned, you may be tested on this.

Offset Lithography

Offset is typically the method of choice for large quantity, commercial jobs like brochures, newsletters or stationery packages. It starts by transferring a photographic image onto a plate (usually made of metal but sometimes made of plastic or even paper). This plate is then mounted on a cylinder where a set of rollers applies oil-based ink and water during rotation. Because oil and water don't mix, ink adheres only to image-based areas. The inked plate then rotates and transfers the inked image onto a rubber, cylindrical blanket which then rotates and applies the ink to the paper running between the cylinders. Why is it offset? The image is not directly applied to the paper, rather "offset" or transferred from the rubber to the paper.

Screen Printing

Screen printing (or serigraphy) has always been a popular method amongst graphic designers for its versatility across mediums. Its most common application and historical origins is t-shirt or textile design. The Japanese started katazome by creating stencils with dried banana leaves and forcing inks or dyes through the openings, resulting in beautifully ornate kimonos. Since the screens are made using a fine woven fabric or pliable material like plastic, they can be used on all kinds of objects like t-shirts, posters, hats, mugs, dvds, pens, shot glasses and any other type of chotcke imaginable.

Thermography

Often considered the cheap alternative to engraving, thermography is an offset process that produces a raised ink effect by adding powder to ink then heating to dry. It is often used in high-end applications from sophisticated wedding invitations to personal stationery. (Why? Because raised letters feel nice when you touch them.)

Letterpress

Letterpress is often used in more formal applications, as in thermography, but has enjoyed a renaissance of sorts in other applications due to its handcrafted appearance and process. As its name suggests, letterpress is the setting of text or flourishes using "movable type," in which the raised surface of each type character is pressed into a smooth substance to obtain the image. Books of old were produced using this high quality method, where individual font families were forged or carved then set page by page, adding to the rarity of first or second edition classics.

Flexography

Also known as "surface printing," flexography is the method most commonly used for packaging, originally developed for printing on corrugated cardboard. Essentially, ink is deposited upon the surface of a plate then rolled onto the printed surface. Because cardboard and other packaging materials tend to have uneven surfaces, this method was developed to maintain consistent contact and pressure between the inked surface and printed surface (thus its need for flexibility). Products often associated with "flexo" include corrugated boxes, retail packaging and shopping bags, food bags and sacks, flexible plastics, self-adhesive labels, and wallpaper.

Digital

Digital printing is all the rage these days with variable data abilities and increased quality combined with cost efficiency. What's not to like about that? It is an ideal source for prototyping and small print runs, enabling tailored messages on postcards based on list demographics. Unfortunately, in large quantities, any cost savings is lost due to the one-off nature of digital printers, not to mention the restrictions on paper size and selection. (Sorry, you won't find any large-scale posters digi-printed on a sweet Speckletone French Paper with metallic ink.) But the technology has come a long, long way in just the last couple of years. Who knows what's next.

Maybe, to your surprise, there is a method to the madness. Sometimes it just takes some good consultation and experienced vendors to find the best fit for the job.

Eager to learn more? Your friendly local printing rep can most definitely help or contact John at jws@untuckdesign.com or 610.355.2330.