To help you gain a better understanding of the different print processes we commonly use, we’ve compiled a list of these processes and a brief explanation of how they work.

D E F G H L O S T

• Digital Printing

  Perfect for short runs due to the quicker set-up times, digital printing has offered a great alternative for small companies whose budgets might not allow them certain print jobs. But, digital also has its limitations. Sheet sizes are usually 12" x 18" or smaller only certain papers can be run on digital presses. Also because the ink sits on the paper, it has a tendency to flake off on score, folds or spines.

• Engraving

  While using a plate to transfer ink to paper just like Gravure, Engraving forces the paper against the paper with great pressure. Most engraving plates are pretty small (4" x 9") and extremely costly.

• Flexography

  Frequently used for printing on plastic, foil, acetate film, brown paper, labels and other materials. It uses flexible printing plates made of rubber or plastic and fast drying inks. It is a high speed process that can print on many types of absorbent and non-absorbent materials and can print continuous patterns such as giftwrap and wallpaper.

• Foil Stamping

  Paper is stamped with a hot die that presses a thin plastic film carrying colored pigment against the paper. Plastic film comes in more than 200 colors, including pearlized effects and metallics, as well as clear foil stamps that mimic the look of a varnish. Because the process can render a completely opaque image, foil stamping is often used to apply a light-colored image against a dark-colored paper. In addition to applications on any paper that can withstand heat, foil stamping is also suitable for pens and pencils, cloth book covers, vinyl binders, toys and other nonpaper applications. When foil stamping is combined with embossing, it's called foil embossing. The process involves applying the foil first and then embossing.

• Gravure

  This process skips the blanket in offset printing and the plate directly transfers the ink to paper. It is a very expensive procedure but provides amazing image reproduction. Due to the high costs of this method, print runs need to be extremely large to make this cost effective.

• Holography

  Holographic or three dimensional imagery is created by digitizing an image so that it is divided into several layers. The process includes bouncing laser beams off of mirrors and focusing them onto a photosensitive plate. The holographic design is then embossed onto coated white paper which is metallized for a shimmery effect. Holography requires working closely with specialized vendors over a period of several weeks, and set-up charges can make the process cost-prohibitive for small run projects. Holography is used on credit cards, trading cards, book covers, beverage packaging and other situations where high-volume make it a cost effective option.

• Lenticular Printing

  This process creates an animated effect where images flip back and forth when viewed from different angles. It is achieved by laminating a plastic lens over two or more images that have been digitized and broken down into a series of dots. Producing a lenticular image requires working closely with a lenticular vendor to produce digital imagery that meets their requirements.

• Letterpress

  Letterpress uses lead letters that are inked and pressed into the paper, leaving an indentation along with the ink. This is one of the oldest forms of printing and can be used to add a more antique or artistic look and feel to your job. Images can also be applied through etched plates. This is a very costly and time intensive method of printing, but can produce beautiful results.

• Offset Printing

  This is the most common used method of printing where an image on a plate is "offset" onto rubber blanket cylinders which, in turn, transfers the image to a sheet of paper. The process is based on making the printing image ink receptive and water repellant, while the non-printing areas are rendered water receptive and ink repellant. Offset presses may have more than one printing unit, with each delivering a different color. They come in a range of sizes and can accommodate single sheets as well as rolls of paper.

• Silk Screen Printing

  A squeegee is pulled across a silk screen to which a stencil has been applied, forcing the ink onto the surface of the paper or substrate. More labor intensive than offset, screen printing is used for printing on surfaces no accommodated on an offset press, such as fabric, industrial papers, acrylic and metal. The process can be done by hand or machine. Halftone screens need to be coarse, ranging from 65 - 85 lpi (lines per inch). Often used for printing signage, bottles, garments and other unusual shapes and surfaces.

• Thermography

  Similar to an engraving in appearance, thermography involves applying powder to a slow-drying ink. After the excess powder is vacuumed away, heat is applied. The curing of the ink and powder causes it to swell, creating a raised impression. Thermographys costs less than engraving and is often used on business cards and stationary. The process is not appropriate for printing halftones or large areas of color, which are likely to have a pitted or mottled appearance.