Small Footprint, Big Possibilities

Hugo Gonzalez, Sr. Segment Specialist, Mimaki USA, contributed to this article.

UV-LED flatbed printing in the direct-to-object space is a transformative technology that enables the production of high-quality images and designs directly onto a wide variety of substrates. Desktop models are available in many sizes from small models with a print area of about 12 inches-by-16 inches to models with more than double the print area. Desktop (also called benchtop) models can do nearly anything that a standard-size UV-LED flatbed printer can do, on a smaller scale. They can be used to augment revenue streams or open up new areas of business.

Many can print to thicker substrates — up to 6 inches or so — which is beyond what some larger flatbeds can accommodate. They operate in the same conditions as larger digital printing systems, and — if they’re within the same manufacturer’s product family — also can share inks, enabling a better chance of color matching between machines and reducing inventory issues.

Textures and colors pop on substrates such as wood.

UV-LED technology is superior to other UV-curing technologies in several ways. UV-LED technology is “instant on,” meaning no warm-up time is required; it draws less power than conventional methods; uses inks without VOCs; and instantly cures the ink enabling immediate printing of the overlay color. This is a timesaver when printing on clear or colored items that require a white backing.

If you’re already familiar with large-format UV-LED flatbed printing, you very easily can integrate a desktop UV-LED printer into your workflow. If you’re not familiar with flatbed printing, the main challenge will be learning to print on the many varied surfaces available. Printer manufacturers and knowledgeable dealers often host mini-expos or hands-on training sessions to teach you the tips and tricks to successful printing.

Use Popular Materials

The versatility of UV-LED curing provides high adhesion and excellent color reproduction across these diverse materials. The most popular materials used in desktop UV-LED flatbed printing are plastics because of their variety, versatility, and cost-effectiveness in producing promotional items and consumer goods. Metals commonly are used for high-end promotional products due to their durability and aesthetic appeal. Stainless steel tumblers, office or award nameplates, and keepsake photos all are examples of how UV-LED flatbed printers are used to print onto metal. Glass and acrylics are popular for their premium look in decorative items and awards, while wood often is chosen for custom, rustic, or artisan products.

For printing directly onto cylindrical objects — whether plastic, stainless steel, or glass — some printer manufacturers offer an adapter for use on their printers. These are devices that can rotate the object 360° while remaining positioned correctly beneath the printheads. With a cylindrical printing system, you can direct-print tumblers, bottles, cans, vases, carafes, packaging, and candle holders, expanding the range of offerings for your business. Some new adapters can print directly to tapered surfaces, further expanding custom goods production to items such as tapered glass tumbler decoration.

With any media, the main issue is adhesion: Finding the right combination of ink, substrate, and in some cases, adhesion promoter. Look for a printer that offers a wide range of UV inks with different flexibilities to best meet your needs. Another common challenge to direct printing is the flatness of the print surface. Look for printers with tools that enable high-quality printing on uneven surfaces, which will help when printing to objects such as the inside of a clear phone cover.

Go beyond conventional Braille signage by printing second-surface details and textured embellishments.

Getting an Edge With Effects

Textured, or 2.5D effects, are ink layering effects that can be printed to add a tactile component to designs such as adding the look of lace to a wedding placard or brush strokes to artwork. Textured effects also enable the production of ADA and Braille signage with available design software and compatible processing software.

The ability to print in gloss and matte finishes and an emboss effect also are available on some models, as well as the ability to create a wide range of metallic color effects. Metallic ink can be used to create value-added imaged products, offering color effects that are in high demand for personalized products, awards, novelty items, and custom packaging. Metallic ink provides a strong competitive edge to offer high-quality, premium finishes. Some UV-LED metallic inks can directly image a surface without the need for added glitter or a foil transfer process.

Vibrant colors can be printed onto dark substrates if the white ink offers enough opacity. UV-LED technology enables the fast curing required so that white and color inks can be printed in the same pass to maintain high production speeds. White ink provides the ability to print on many clear or colored surfaces, on either the front or back — or sometimes both.

Desktop printers can often print directly to thicker items such as this clutch, to create custom gifts.

A Wealth of Applications

Personalization always has been a solid revenue generator for flatbed owners, and now the hyper-personalization market is growing. Phone cases, chargers, and USB drives always have been very popular, as well as stainless steel beverage containers. The ability to customize objects in a real-time workflow and deliver with a quick turnaround has increased the demand for specialized printing services and equipment. You can augment existing business, for example, if you’re producing large signage for a local event — say a golf tournament. A desktop UV-LED flatbed printer enables you to produce complementary items such as personalized golf pencils and scorecards, souvenirs, water bottles, golf balls, and awards instead of referring that business to another shop.

ADA signage also is a growing area. When most people think of ADA signs, the image of raised letters and Braille on a solid background comes to mind. Clients today want more than cookie-cutter signs. They want a consistent theme, or branding, that requires more than simple plastic badges. Using a desktop UV-LED flatbed printer, a clear acrylic panel can be second-surface printed to display the visual directionals, with the textured, Braille components printed onto the first-surface area.

Complementary technology can combine to open new avenues for revenue generation. If you own a desktop UV-LED flatbed printer and a laser cutter, they can be used independently for regular graphics business or can be used together to produce award personalization for employee recognition, and team and individual sports. For example, acrylic blanks can be reverse printed with the company, team, or event name, and be held until needed. The individual’s name and statistics (if necessary) can be added by printing or laser etching at a later date.

Print labels or directly to cylindrical objects with an accessory, to create bespoke product displays.

More Opportunities

Adding desktop UV-LED flatbed printing to your operation gives you an advantage by providing opportunities to deliver creative and unique products. The addition of cutting and engraving products with cross-connectivity through software has helped expand this space. For many, it also enables them to express their creativity using digital technology with complete control over the results. There also is great potential where the “maker” market meets a creative market.

Direct-to-object printing using UV-LED desktop flatbed printers will continue to evolve. As technology advances and printing processes become more efficient, you’ll continue to see improvements in print quality, speed, and the range of materials that can be printed, and the materials that make up the ink to enable a wider range of uses. Also as AI advances, it will be a source of predictable workflows where algorithms are deciding outcomes rather than opinions. and accuracy.