Traditional Printing Processes

P RINTING is the production of an

image onto paper or other
substrate. Traditional printing
processes include lithography, screen
printing, flexography, gravure, and
digital. The global print industry is worth
$898 billion and drives $3.8 trillion in
related services. The direct and related
services include: $133 billion in online
advertising, $15 billion in music industry products, $102 billion in video game industry
products, and $1.1 trillion in the U.S. auto industry.

Objective:

þ Define basic printing terms and describe traditional printing processes.

Key Terms:

Ñ digital printing
electroplating
intaglio printing
lithograph
printmaking
registration
flexography (flexo) lithography registration mark
gravure (rotogravure) offset printing (offset relief printing
printing lithography) screen printing
image plate substrate
incise plating
inkjet printer printing

Printing Terms and Processes

BASIC PRINTING TERMS
Printing is the production of an image onto paper or other substrate. Printmaking is an
indirect means of creating art by transferring an image or design to a surface (typically, paper)
by use of contact with a block, plate, stone, or screen.

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 Substrate
A substrate is the base material onto which an image is printed. Examples of a substrate
include paper, fabric, glass, and metal.

Image
An image is a visual representation, depiction, or likeness of a physical object or person.
Images may be paintings, pictures, or digital displays. Various traditional printing methods cre-
ate an image obtained from a printing element. Customarily, the printing element was a metal
plate, an intaglio engraving, a wood block, or a metal plate cut in relief.

Intaglio
Intaglio (pronounced “in-
TAL-ee-oh”) printing is a
printmaking technique where the
image is engraved or incised onto
the surface and the printing is
done from ink that is held in the
lines or sunken areas below the
surface of the plate. Incise means
to mark with a cut or series of
cuts. An intaglio print is the
opposite of a relief print. Intaglio
is mainly used for stamps and FIGURE 1. U.S. postage stamps are created using an intaglio gravure
paper currency. engraving (scratching, etching) process and/or an offset printing process.

Relief
Relief printing is a
printmaking technique in which
the image to be printed is raised
from the surface of the printing
plate. The surface around an
image is cut away so the image
appears “in relief” on the printing
plate. The printing plate is inked
and pressed onto a printable sur-
face. This creates a relief print.
The process is similar to using an
ink pad and rubber stamp. Relief
printing is sometimes referred to FIGURE 2. In the sketched image, “A” is the block and “B” is paper media.
([Link]
as block printing.

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 Registration
Registration is the precise alignment and placement of printed images. Proper registra-
tion means that any impression on the paper occurs in the exact position as intended. The
images are positioned with reference to each other or to margins, folds, etc. Registration is
affected by movement of paper as it runs through production equipment and by the mechani-
cal settings on such equipment. Registration uses either visual reference lines (register marks)
on the copy or mechanical methods of alignment.

Colored Ink
Printing presses are able to apply multiple colors or styles of ink onto the same surface. A
registration system is always used when more than one application of ink is required. Registra-
tion marks ensure that the paper is aligned in the exact spot every time and that the colors of
ink are applied in the proper place.

Registration Mark
A registration mark is a cross-hair line
(target) outside the page or image area that is
used to help align color separations or to align
the printed images on the press sheet. The mark
appears on all separations. The most common
use of registration marks is in the production of
multicolor documents, brochures, flyers, post-
ers, T-shirts, etc. The manufacture of those
items requires that each color is applied in a sep-
arate step. Registration marks are required on
any substrate that is processed multiple times
through an offset printer, a rotary press, or a
screen. FIGURE 3. Registration marks are required on any
substrate that is run through an offset printer, or rotary
press, or screen process multiple times.
Plating
A plate is the tool that transfers an image onto paper or other substrate. Plates may be
made of metal, paper, or plastic. Plating is the process of applying a metallic coating to a sub-
strate material.

Plating Technique
Electroplating is a chemical process that uses an electric current to deposit a thin layer of
metal onto the surface of a work piece (substrate). The process is performed at low tempera-
tures and it can be used on Various types of a substrate. Other types of plating include vapor
deposition, vacuum, and sputter deposition.

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 Usage
Plating is used on plastics or other materials that require a protective coating or need a
metallic finish. It is used on machinery parts to help resist corrosion, oxidation, and the effects
of humidity. 3D printed plastic models can be plated to add metallic decorative coatings. The
coating is also used to create reflective surfaces, add circuit paths (conductivity), and improve
durability.

TRADITIONAL PRINTING PROCESSES

The major commercial printing processes are lithography, screen printing, flexography, gra-
vure, and digital printing. Each method is distinctive. The choice of method depends on such
factors as the type of image to be reproduced, the production cost, the time frame for produc-
tion, and the amount of printed material that is needed (size of the print run).

Lithography
Lithography is the process of printing from a smooth, flat plate (limestone or metal) on
which an image is applied with a greasy medium. The image will repel water and accept oil-
based ink. The blank area on the plate will repel ink. It is a method of printing based on the
principle that oil and water do not mix. A lithograph is a picture created by using a smooth
plate on which an image has been drawn with an oily, chemical substance that attracts ink.

Traditional Lithography
Traditionally, the image or art-
work is drawn or painted on a flat
surface with an oil-based ink or sub-
stance. Then, the work is fixed with
a chemical solution. Next, the sur-
face is covered with water that
absorbed onto the surface in all areas
except where the oil-based image is
located. Oil-based ink is then rolled
onto the surface to rest only atop of
the originally created image (that
was drawn with oil-based materials).
Finally, paper is pressed onto the flat
surface to absorb the ink and create
the image. One color at a time is FIGURE 4. Lithographic images were historically “drawn” onto a stone or
printed and, usually, one color is metal plate. Then, the image was fixed with a chemical solution, washed, and
ink was applied. Next, the image pressed onto paper or another substrate to
printed per day. This is a painstak- create fine art prints and reproductions such as this Japanese wave art print.
ing, time-consuming process
performed by hand.

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 Modern Lithography
Modern lithography utilizes images that are transferred photographically and then prepared
using a nontoxic chemical coating. The image can be printed directly onto paper or it can be
offset by transferring the image onto a flexible sheet (rubber) for printing and publication. Off-
set printing (offset lithography) is a printing technique that transfers ink from a plate to a
rubber blanket (an intermediary cylinder) to paper instead of directly from plate to paper. This
damping, inking, and printing process is rapidly performed by a series of rollers. It is the most
common form of commercial printing.

Usage
Tradition lithography has historically been used to create fine art prints and quality repro-
ductions. Modern offset lithography is used for long to medium print runs of books, maga-
zines, posters, and packaging products.

Advantages and Disadvantages

Offset printing produces a consistently high image quality, even on large print runs. How-
ever, the product image is of less quality than that produced by gravure printing. The set-up
and production time is fast. Printing plates have a long life, since the plates only come in con-
tact with the printing blanket rather than the more abrasive paper. The production costs are
inexpensive. However, the costs for a small print run are high.

Screen Printing
Screen printing is a stencil method in which ink is wiped across a mesh screen, pressing
the ink through the openings on the screen and onto the substrate below. One screen is used
for each color printed. The screens must be registered to ensure that all the colors line up cor-
rectly. Each color is applied using a different stencil, one at a time, combined to achieve the
final look. This method of printing is sometimes called serigraphy.

Steps of Screen Printing

There are few steps in screen
printing. Basically, a graphic
image is created in the form of a
stencil pattern and applied onto a
mesh screen. The screen is
stretched onto a frame and fixed
into a position on a press. Ink is
placed inside the frame and
rubbed across the surface, typi-
cally with a rubber squeegee. The
ink passes through the open areas
of the screen, printing the image
onto the substrate. FIGURE 5. The screen printing process transfers ink onto a substrate, except
in areas made impermeable (resistant) to the ink by a blocking stencil.

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 Advantages
The screen printing process can be used on almost any material. T-shirts and other cloth-
ing, plastic items, signs, and posters may all be screenprinted. Screens are inexpensive and they
are quickly produced. The same screen can be used multiple times and the graphic on the
screen will not wear off easily.

Disadvantages
Because ink must be pushed through a screen, creating color gradients is difficult. Multiple
steps are required to print individual colors. Complex details are few in screenprinted items.
Screen printed images are of moderate quality.

Flexography
Flexography (flexo) is a relief printing method in which
an image on a flexible printing plate is inked and the inked
image is transferred to the substrate. This is a modern version of
letterpress printing (using a stamp to transfer ink). Flexography
uses a flexible rubber plate etched with a slightly raised design.
These etched plates are wrapped around rotating cylinders on a
press. At high speed, the cylinders rotate around a reservoir of
ink and press the ink onto the substrate. The substrate can be
paper, as well as plastic, metal, or other materials. Flexography
has typically been used to print labels and packaging materials.

Advantages
This method is suitable for both absorbent and nonabsorbent
materials. Flexography uses both water- and oil-based inks.
Flexography is quick (quicker than gravure printing) and eco-
nomical.

Disadvantages
Flexography produces less complex graphic images. The
FIGURE 6. Most soda bottles or
edges are not crisp and the colors are less bright. The product beverage labels have plastic labels
images are of lesser quality than those produced by gravure produced by flexography printing.

printing.

Gravure
Gravure (rotogravure) printing is a type of intaglio printing process in which an image
is etched on the surface of a cylinder and paper is pressed against the inked cylinder on a rotary
press. The image is transferred directly to the paper, unlike offset printing, which uses an
interim cylinder. This is a quick and simple printing process that consistently produces high
quality images but gravure is also expensive. The set-up cost and the cost of engraving the cyl-

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 FURTHER EXPLORATION…
ONLINE CONNECTION:
How to Create a Screenprint
Screen printing is a relatively simple process
compared to other traditional printing processes.
You can buy all the materials needed at a local art
store and create your own innovative and creative
prints. To learn more, go to
[Link]

Manual screen printing tools, equipment, and materials are

easily accessible.

inder are quite high. Because the production costs are quite high, gravure is cost effective only
for long runs. Like flexography, gravure is often used for long runs of high-quality, multicolor
printing. Products printed by gravure include postage stamps, wallpaper, and gift wrap.
Because gravure produces fine, detailed images, this process can be used for large runs of very
high quality art and photography. Where photographs are being reproduced, this printing
method may be called photogravure.

Digital Printing
Digital printing is a method
in which an image is sent from a
computer file directly to a device
that accepts texts and graphics.
Digital printers put the image
directly onto the substrate. Digital
printing, unlike other printing
methods, does not require a
printing plate. The advantages of
digital printing are low produc-
tion costs and fast turnaround
time. However, ink and substrate
options are limited. This print
method is ideal for short print
runs and customized print media.
Digital printing is commonly
used for one-of-a-kind prints and
FIGURE 7. This abstract owl image is an original digital “painting.” It can be
posters, large-scale billboards and reproduced as a print, poster, billboard, etc.
signs, photographic prints, and

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 flyers. The two types of printers that dominate the field of digital printing are inkjet printers
and laser printers.

Inkjet Printer
An inkjet printer produces an image by spraying liquid ink onto a substrate. The process
leaves tiny dots of ink, which from a distance, appear as a continuous image. Typical inkjet
printers produce copy with a resolution of at least 300 dpi (dots per inch). They are commonly
used for documents, posters, and signage.

Laser Printer
A laser printer applies a charge that attracts toner and that toner is then transferred and
fused into the paper. Laser printers are frequently used in offices to produce documents. They
can also be used to produce small run printings of books, brochures, direct mailing materials,
bank statements, etc.

Summary:

2 Printing is the production of an image onto paper or other substrate. Traditional

printing processes include lithography, screen printing, flexography, gravure, and
digital. Each method is unique and requires you to determine the necessary and
appropriate criteria for creating a successful print: quantity, quality, substrate, and
use.

Lithography is typically used on long to medium print runs for magazines, posters,
books, and packaging products. Screen printing can be used on almost any material.
Flexography has traditionally been used to print labels. Gravure is used for long
runs of high-quality, multicolor printing. Digital printing is commonly used for
one-of-a-kind prints and posters, large-scale billboards and signs, photographic
prints, and flyers.

Checking Your Knowledge:

´ 1. What is your definition of “printing?”

2. Describe the five major types of traditional printing processes.
3. How do printers use registration marks?
4. What is an advantage of gravure printing? When would a printer select gravure
as the print process?
5. What is a disadvantage of using digital printing?

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 Expanding Your Knowledge:

L Plan a trip to a local printer. Most large printers offer a range of printing options to
their customers. Talk to a local printer and observe as many print processes as possi-
ble during your visit. If possible, take pictures of processes to share with your class-
mates.

Web Links:

: Gravure
[Link]

Printmaking Processes
[Link]

Registration
[Link]
registration-mean/

Rotogravure
[Link]

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