The Next Generation Flexography - Direct Laser Engraving

image credit: Cary Color Inc.

Direct laser engraving (DLE) sleeves, cylinders, and plates are a new trend in flexographic printing. New laser technologies appeared at the turn of the century. YAG and diode lasers began to be used more often in the plate-making process, initially primarily for mask ablation, but subsequently for direct laser engraving as well (DLE).

These innovations were picked up by many engraving system manufacturers, who built their systems around them. The expense of many processing stages and equipment associated with more traditional photopolymer sleeve/plate production processes is eliminated with direct laser engraving technology for flexo.

Single or many high-powered carbon dioxide or fiber lasers are used in flexographic engraving systems to directly etch continuous sleeves or plates in a single step. Without the use of exposures or chemicals, the laser selectively ablates the non-print area of an elastomer plate or sleeve to produce a print-ready surface.

Direct laser engraved plates or sleeves essentially prevent misregistration, ink transfer, and plate swelling on the press, it is ideal for flexo printing. This is especially true when an image on elastomer sleeves is created via direct laser engraving.

DLE will be a force in the flexo industry for years to come because of its efficiency, quality, and cost advantages.

 

Elastomer Sleeves vs. Polymer Sleeves

 

Elastomer sleeves have been held back in America because to cost, perceived supply chain issues, and restricted inventory, but new breakthroughs in imaging and manufacturing are bringing their inherent benefits to the attention of printers.

Elastomer sleeves are thicker and more robust than polymer sleeves, and they can print for two to four times longer. This removes the need for several plates or polymer sleeves for long runs and frequent, abusive short runs that necessitate numerous cleanings and press cylinder mountings, resulting in long-term cost savings and predictability. "Elastomer normally costs less than polymer, and we're only buying one set instead of two—so the savings are great, and our print results are more consistent," said printers who have moved from polymer to elastomer sleeves.

 

Future Industry Projections for Direct Laser Engraving

 

Whether you're printing flexible packaging, pressure-sensitive labels, medical labels, and packaging, or working with more delicate substrates like tissue and non-woven, direct laser engraving has become increasingly crucial. Here are some market forecasts for several flexographic applications:

 

1- FLEXIBLE PACKAGING

 

To boost production efficiency in the fast-paced flexible packaging business, higher-speed printing is required.

Sleeves with lasers are the epitome of efficiency. Furthermore, laser-cut sleeves enable quicker press rates. Pre-press mounting takes less time, and it eliminates the requirement for press downtime to remount and retape flat plates.

Reduced chance of warped images due to misalignment also means reduced delay on the press and wasted substrate while attempting to locate the appropriate register.

 

2- LABEL PRINTING

 

Labels work best with laser-engraved elastomer sleeves. Elastomer’s physical properties work well with all sleeve sizes needed to print any size label. Expect DLE growth in this market as the technology progresses and becomes more commonplace, particularly as it pertains to pharmaceutical/medical labeling and packaging.

 

3- CORRUGATED PACKAGING

 

Mounting flat plates takes time and creates the potential for registration problems. The corrugated industry knows the issue of misregistration well.

 

Desperately need quality production on the press? Laser ablating elastomer plates and sleeves are now more precise than ever. Precision equals high definition.

 

4- SPECIALTY PACKAGING

 

Traditional plates simply have their limitations. Jobs requiring higher ink densities, higher line screens, and smoother vignettes also can benefit from DLE. Packaging like this (often used for liquid carriers and non-perishable food items) typically requires ultraviolet-cured inks, which work best with elastomer sleeves.

 

5- PRINTED ELECTRONICS

 

In this case, you especially need to avoid the harmful effects that abrasive inks and strong solvents can cause. Again, elastomer plates being ideal for UV inks, in turn, is ideal for this printing application.

Direct laser-engraved sleeves also are perfect for the fine detail required.

 

DLE Sleeves Bring Quality, Efficiency, & Fine Detail

 

One of the biggest advantages of in-the-round direct laser engraving is reversed-out text. The industry is long past overlooking misregistration issues and problems with press downtime for mounting and troubleshooting mistakes. The industries you serve move quickly while still demanding quality printing capabilities.

You can’t afford to leave both quality and efficiency to chance.