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Die-cutting, Foil Stamping and Embossing

Mark CupachDirector, National SalesBASICS OF PRINTING

1Todays webinar session addresses another production element of the printing process. After the images have been printed onto paper or other substrates, at times, special operations like foil stamping, embossing or die-cutting can enhance the design and purpose of a printed document.This webinar will explore these types of enhancements and present a clearer understanding of how they are produced.Finishing StandardsCorrect finishing is usually sequentially pre-determinedFinishing is a determining factor in how jobs are printedMaster Shell / Imprint ProgramsThe more you finish..the more you scrapIn-line vs Off-line..Its all in the quantity

2Most finishing operations are dictated by the final design or use of the printed piece and many operations are sequentially pre-determinedie..you need to fold a large press sheet before you can bind it.you need to foil stamp or die-cut a press sheet before you glue and fold it..like a presentation folder..

How a job lays out to be printed is also determined by what is going to be done to it in the Bindery..ie.printing a 16 page booklet with a final size of 8.5 x 11. Easiest way to make it into a booklet is to print the pages in a certain sequence on the press sheet so that when we fold it 3 times, all the pages are in the correct sequenceIn stationery, the use of master shell and imprint programs require the pre-printing of shell stock for imprinting One thing to keep in mind is that the more operations you submit a job to, the more paper you need..printing press makereadies require anywhere from 50 to 100 extra sheets of paper per color, every finishing operation requires set up time and press sheets to register the machine to and thats all added to the intended delivered quantity in order to determine how many initial sheets are needed to start the job.

some larger commercial web presses have in-line folding because its more economical than running all those press sheets thru another operation..FinishingStraight-cuttingChop Cut / Guillotine CutProgrammable Cutters

3An operation that literally every printer MUST have is Straight cutting. Its also known as chop cutting or guillotine cutting

modern cutters are programmable so that whatever series of cuts that need to be made to make BIG sheets into a lot of SMALLER sheets can be input just one time and the machine cyles thru all the cut moves automatically.

Polar Computer Programmed 52 Trimmer4Here is a modern cutter that can handle 52 sheets...the cutter operator runs thru a series of pre-determined cuts to make big sheets into little sheets. Each cut sequence is programmed into the cutting machine so the machine automatically sets the cutting table for each following cut that needs to be made.

5Here, a smaller cutter but still programmablea scissors jack keeps the stock at waist height to keep the operators lifting minimized..Die-cuttingHigh or Hollow Die-cuttingUsed for Single Labels and Envelope Converting

Steel Rule Die-cuttingFor Large areas and where close register is requiredDie Line art required for Die ProductionLaser cut lines for Rule insertionDiffering rule typesCutting / Perfing / Scoring

6The next operation that many.but not all printers have, is that of die-cutting.There are two types of diecutting----The first type of diecutting uses High, or hollow dies that are used to diecut label and envelope blanks.The second type of die used in commercial printing is steel rule die cutting.Steel rule dies are used for close registration workTo produce a die, a special piece of artwork called a die line is used as a pattern to cut the rule lines into hard maple wood.Laser cutting machines are used to gain a high level of accuracy and the rule in inserted.There are 3 types of rule used in cutting dies. The first is actual razor sharp cutting rule, the second is a toothy edge rule that will apply a perforation to the paper and the third is scoring rule which places a channel into the paper to make folding easier.

Standard Cutting Die

7Here is a top view of a die..

Cutting rule that has the rubber along its edges to help push the paper stocks up off the rule after it has been cut

Perfing rule that also has the rubber edges

Scoring rule.there are no rubber edges along the scoring rule because this type of rule will not penetrate the paper all the way thru..just putting in a nice channel for a smoother fold.

Die-Cut Make-ready

8Here, a die has been selected and the make-ready process for setting the machine up has started.The die is put in the bed of the press and spacers are used to center the die to match how the press will pull the sheet thru and make contact with the cutting rule..

Locking up Chase on a Heidelberg Cylinder9After the die is centered where it needs to be and registered to the sheet, it is locked down so it cant move.

Cutting Die Set-up for a Presentation Folder10Now the sheets are ready to be pulled thru the die-cutting press.as the sheet is pulled thru, the bed slides into the press and the sheet is pushed against the die by the impression cylinder much like the impression cylinder is used in printing to push the sheet against the rubber blanket to offset the ink.

Foil StampingUses Dies of image pressed against stock over a colored ribbon of foilCan be registered to either printed inks or to embossed imagesFor stationery, usually run as masters then imprinted

11Foil .or Hot Stamping is another process in the Finishing area.Dies of typically magniesium are used to press paper stocks over rolls of foil.Foils come in rolls..and can be purchased in many colors. Look in the catalog of many presentation folder companies and you will even see their selection of what they consider Stock foil colors.Foil stamping is a highly controlled operation, especially if it requires registration to an ink color already printed on the paper or to an embossed image.In the stationery markets, foil stamp business cards are typically run as a master shell / imprint program because it is cheaper to run an annual quantity of masters one time than to foil stamp individual orders as they are needed.

Foil Stamp Die

12Here is an example of a foil stamping die. The image area to be pressed against the foil and onto the paper substrate is a raised image on the metal.

Angled View

13Here is an angled look of the die to more clearly view the raised image area.

Foil Roll Mounted to Press

14The foil stamping press in this picture has a red foil roll mounted to the press and runs through the press to a take up roll.

Stock Feed to Die

15Looking into the press, you can see the foil stamp die peeking out from behind the foil. As the envelope in this case is fed into the press, the two beds come together and the envelope is pressed up against the foil roll and the die presses the red foil onto the envelope.

Stamp Impressions

16Here, you can see the used portion of the foil roll from the back side of the foil. It is critical, in foil stamping jobs, to accurately measure the foil image area because foil rolls come in many different sizes. In this case, a lot of waste has occurred due to the fact that the image area stretches out horizontally with only one line of type being foiled. This roll is unuseable after this job.

17The final product shows a foil stamped logo and company name in the corner copy section of the envelope.

18Here is another example of a foil stamped envelope, but one that is much more economical than the previous example given the size of the foil image area.

Foil Stamp Die in press

19Here are dies mounted on a press in another example.

Rolls of Foil Feeding into Press

20Rolls of gold foil were mounted and are being pulled thru the press..over the dies with pressure transferring the foil from the roll to the stocks.

Important thing to remember is that most printers will want to know the Image size to be foiled and how many locations on a piece will be foiled.rolls come in varying sizes so wasting foil can be a costly addition to your quote if not calculated properly..

Business Card Masters

21This is an example of a business card master program. This 12 up business card master used 3 narrow rolls of foil which was much more economical than using one wide roll to cover the area needed.The masters are then inventoried and used on demand when business card orders are received.Embossing/DebossingEmbossingRaised Image formed by pressing stock between a female die and male counterRegister to printed image or a Blind embossDebossDepressed Image formed by pressing stock between Male die and female counter

22Another finishing operation that many customers desire is that of embossing or debossing.

Embossing is the raised image formed by pressing stocks between a female die and a male counter-die.Embossed images are usually dictated by the design of a printed piece. Embossed images can be registered to printed inks or to foil stamped images.An embossed image without any ink or foil is called a Blind emboss.

Debossing is the opposite of embossing. The depressed image is formed by pressing stock between a Male die and a female counter die.

Embossing Die

23Here is a shot of an embossing die.the depressed areas of the die are pressed against the paper stock and the image is pressed into the paper.

Emboss die in press

24Here is a die mounted into the press..

In-House Embossing

25Again, like foil stampingmany printers can do embossing in-house.

A rule of thumb but not etched in concrete is that if a printer has in house foil stamping capability.they can probably do embossing as well..

Blind Emboss Image

26This is an example of what a blind embossed image looks like.

Multi-Operation Example

27Here is an example of several of the operations we have discussed. Examples of the emboss and debossing operations are seen vertically in the middle of the sheet.8 different foil colors are depicted here in two different options. The column of foil squares on the left are simply applied to the flat paper stockThe right column of foil stamped squares are registered to an embossed square that has been embedded into the stock.FinishingCritical Quoting VariablesTypes of Required Finishing

Embossing and Foil StampingNumber of locationsSize of emboss/foil areas

Die-cuttingArt for Die-line for cutting die

28In the end, the best designs and high quality color printing can be diminished by errors in the finishing.

When getting ready to quote a job.you need to ask questions about any unique rf peculiar finishing that the job may need..

Is it just a folding job? Is there die-cutting? Embossing? What type of binding method and will it work?

For embossing and foil stamping, how many locations and size of image area to be embossed or foiled.

For die-cutting..who is supplying the art for making the die if new.and if a standard dieis the artwork prepared adequately to cover bleed requirements.FinishingRecapPrint Layout is directly linked to what finishing operations are requiredDifferent Die types for different types of operationsNew..custom jobs need new diesStock or rerun jobs use stock diesUp-sell premium services when possible

29Lets recap our session.Most finishing operations like foil stamping, die cutting and embossing are dictated by the design of a printed piece. The finishing operations are used as a design enhancement or to produce some utility in the final product.There are different types of dies used for each operation. If the design is new, a custom die will be needed and there is a die charge that will be required.For standard presentation folders and envelope products, most printers who do die cutting should have a standard hanging die in storage to produce the job.Foil stamping and embossing are enhancement operations and in some products like stationery and envelope products, can be an up sell feature to grow revenue in a product.

in the end..and we truly are at the end of our print jobits important to realize that all aspects of the printing process need to run smoothly to insure the correct and acceptable printing of your customers job.Business Stationery hopes that this webinar about finishing operations has helped you understand the different enhancements used by many designers and customers to add value to their printed collateral.