1.19 The Use of Finishes Flashcards
(49 cards)
Paper and Board Finishing
Lamination via encapsulation
Lamination via encapsulation refers to a finishing process where a plastic film is applied to both sides of a sheet of paper or board, with the film extending beyond the edges, fully sealing and protecting the paper inside. This creates a durable, waterproof, and wipeable surface.
Unlike standard lamination, encapsulation wraps the paper entirely, with a visible plastic border.
The paper is “encapsulated” between two sheets of film that are sealed around the edges using heat and pressure.
Think of it like laminating an ID badge or menu—the plastic is larger than the paper and completely surrounds it.
Paper and Board Finishing
Lamination via a surface coating
It involves bonding a thin plastic film (usually using heat and pressure) or applying a liquid coating to the surface of paper or board. This process “laminates” the surface, giving it added protection and often a more premium look.
- Film Lamination
A thin plastic film (like BOPP, PET, or PVC) is glued to the surface.
Finishes:
Gloss – shiny and vibrant, good for color enhancement
Matte – smooth, non-reflective, premium feel
Silk/Satin – in-between finish with a soft touch
- Liquid Coating (Surface Coating)
A liquid layer is applied and dried to form a protective finish.
Common methods: UV coating, aqueous coating, varnishing
Paper and Board Finishing
Embossing
Creates a raised design on the surface of the paper or card to give a visual and tactile effect (greetings cards, chocolate box lettering)
Paper and Board Finishing
Debossing
Debossing is the opposite of embossing: it creates a sunken (recessed) design or text on the surface of paper or board by pressing it downward into the material.
A metal die is pressed into the material without a counter-die, pushing the design into the surface. The result is a depressed image, which may or may not include ink or foil.
Like embossing, it can be done with or without heat, and with or without ink/foil.
Produces an imprinted depression that sits below the surface of the paper or card
Paper and Board Finishing
UV varnishing
UV varnishing is a surface finishing process where a clear liquid varnish is applied to paper or board and then cured instantly using ultraviolet (UV) light. It creates a smooth, durable, and often glossy finish, enhancing both appearance and protection.
Key Features of UV Varnishing:
Fast drying – cured instantly with UV light
High gloss or matte finish
Enhances color vibrancy
Scratch- and moisture-resistant
Can be applied to specific areas (spot UV) or the entire surface (flood UV)
Paper and Board Finishing
Spot varnishing
Applied in specific areas or spots rather than to the whole surface area
Paper and Board Finishing
Foil blocking
Foil blocking (also known as foil stamping) is a premium finishing process where a thin layer of metallic or pigmented foil is applied to paper or board using heat and pressure. It adds a shiny, reflective, or colored effect to specific areas, like logos, titles, or decorative elements.
Adds elegance and visual impact
Creates contrast and emphasis on key elements
No ink required – perfect for bold effects
Works well with embossing for a raised metallic finish (called combination blocking)
Paper and Board Printing
Screen Printing
Screen printing is a printing technique where ink is pushed through a fine mesh screen (stencil) onto a surface, in this case, paper or board. It’s a manual or semi-automated process, ideal for bold, vibrant designs, especially on textured, thick, or specialty stocks.
Advantages:
Can print on heavier/thicker materials that other printers struggle with
Excellent for metallic, fluorescent, or specialty inks
Works on non-flat or textured surfaces
Highly durable and opaque, even on dark materials
Limitations:
Best for short runs – not economical for high-volume printing
Limited detail compared to digital/litho printing
One color at a time – multi-color designs require separate screens
Slower and more labor-intensive than digital methods
Paper and Board Printing
Flexographic printing
Flexographic printing (often shortened to flexo printing) is a high-speed, rotary printing process that uses flexible relief plates to print on a wide range of materials, especially packaging materials like corrugated cardboard, paperboard, labels, and cartons.
- Four colours (cyan, magenta, yellow, key (black)) are printed on top of one another in various quanties on to the substrate surface to create the print colour required.
- It is used for newspapers, comics, catalogues, folding packaging cartons, labels, carrier bags and continous pattern products such as wallpaper and gift wrap.
Paper and Board Printing
Advantages of flexographic printing
- High print speed
- Ideally suited for the long run
- Prints on a wide variety of substrate materials
- Low cost of equipment and consumables
- Low maintenance
Paper and Board Printing
Disadvantages of flexographic printing
- The cost of the printing plates is relatively high, but they last for millions of print runs
- Takes a large amount of substrate to set up the job; excess material may be wasted
- Time consuming to change for any alterations to the print content
Paper and Board Printing
Offset lithographic printing
Offset lithographic printing (or simply offset printing) is a high-quality, cost-effective printing method used mainly for medium to long print runs on flat surfaces, such as paper, board, and packaging materials.
It’s one of the most common commercial printing processes for magazines, books, brochures, cartons, and more.
How Offset Lithography Works:
A metal plate is prepared for each color (usually CMYK).
The image area attracts ink, while the non-image area repels it using water (based on oil-and-water repelling principle).
Ink is first transferred to a rubber blanket, then offset onto the paper — hence the name.
The paper or board runs through multiple cylinders for each color.
Paper and Board Printing
Advantages of offset lithographic printing
- Consistently high image quality
- Suited to higher-volume print runs of 1000 or more
- Quick and easy production of printing plates
- Long life of printing plates because they only come into contact with the printing blanket, which is softer and less abrasive than substrate
Paper and Board Printing
Disadvantage of offset lithographic
- Expensive set-up and running costs for small quantities
- Best for flat paper and card only
- Plates wear faster, suitable for moderate runs
Paper and Board Printing
Digital printing
Digital printing is a modern, direct-to-surface printing method where digital files (like PDFs or images) are sent straight to a printer, with no printing plates or setup required. It’s ideal for short runs, personalized prints, and quick turnaround jobs.
A digital file is loaded into the printer (e.g., laser or inkjet).
The printer applies ink or toner directly onto the material.
The print is either heat-cured (toner) or air/UV dried (ink).
The product is immediately ready for cutting, folding, or binding.
Polymer Finishing
Overmoulding
Overmoudling is moulding a second polymer over specific parts of a products
- TPE (thermoplastic elastomer) is often used
- Overmouldings provide areas of grip or texture
- Overmoulding can highlight different colours for different component Polymer Finishing parts on the product
Polymer Finishing
Two injection moulding moulds
- One mould for the product and one mould for the grip areas
- Product is injection moulded, then placed into a second mould where the overmoulding polymer is injection-moulded on to the body
Polymer Finishing
Twin-shot injection moulding
- The injection moulding machine has a mould designed to produce the product in one cycle
- The mould has two separate component cavities and can be rotated through 180° so that they line up with the twin injection points
- First, the main product part is created in the first mould cavity
- The mould opens slightly and rotates 180° to the secondary position
- The mould closes and the second injection applies the overmould
Polymer Finishing
Acrylic spray paints
- Fast-drying
- Water-soluble paint
- Water resistant when dry
- Improves aesthetics and provides additional protection against the effects of UV light and weathering
- Often used for mass customisation, particularly in the automotive industry, such as colour coding bumpers and wing mirrors on cars.
Polymer Finishing
Adding pigments
- Provide colour to the polymer
- Smart pigments such as thermochromic or phosphorescent pigments can be added
- Can also be added to gel coats when laying up GRP
Metal finishing
Cellulose and acrylic paints
- Provide colour and a textured finish
- Provide a barrier against corrosion
- Specialist paints provide texture or special graphic effects such as pearlescence
- Primarily used on low-cost metals such as steel.
Metal finishing
State the method of application of cellulose and acrylic paints
- Paints are primarily used on low-cost metals such as steel. The surface of the metal is cleaned and degreased, which ensures that the primer coat has a sound surface to ‘key’ (or grip) to
- Red oxide primer is often used, followed by an undercoat in a similar colour to the final top coats
- Paints can be applied by brush or spray
Metal finishing
Electroplating
- A protective layer, a more hardwearing finish, and enhanced aesthetics
- The product and donor material are placed in a container with an electrolyte solution. As the direct current is applied, the product attracts the donor metal and the product is electroplated.
- Metals for electroplating include sliver, gold, zinc, copper and tin
Metal finishing
State the method of application of electroplating
- The product and donor material are placed in a container with an electrolyte solution
- As the direct current is applied, the product attracts the donor metal and the product is electroplated
- Metals used are sliver, gold, zinc, copper and tin
