Pad Printing - FAQ

ALWAYS A RECURRING TOPIC:

TROUBLESHOOTING IN PAD PRINTING

Even though pad printing is the most difficult of all printing processes to troubleshoot, as the multitude of factors can cause more than one error, we've provided a downloadable list of keywords. If this helps you remember a single source of error that you simply forgot to consider, we're happy to be of assistance.

Of course, our pad printing consultant, Mr. Manfred Lumpp, is also available to assist you.

Phone: 0163 / 8979803

E-mail:lumpp@schlee.cc

Pad does not absorb color in places

Caused Solution
Ink too thick Dilute
dried up Clean plate with thinner
wrong thinner choose a slower/appropriate thinner
Plate too flat use deeper plate
wrong grid use a different grid
mechanical damage new plate
Pad too flat use a steeper pad
Surface roughened new pad
Silicone swollen Blow air onto pad, better: new pad
Surface oily Clean pad with solvent
Miscellaneous Contact pressure of pad on plate too high Reduce pad lift

Pad releases color poorly

Caused Solution
Ink Ink dried on the pad use slower thinner
Ink on the pad too wet use faster thinner
Plate too flat use deeper plate
too deep use flatter plate
wrong grid use a different grid
Pad wrong shape use a steeper pad
Surface rough/worn new pad
Printing material Surface contaminated Pre-clean/degrease parts
Miscellaneous Cycle rate too slow increase
Room temperature too high Optimal temperature: 18-20 ° C

Coverage is insufficient

Caused Solution
Ink too thin Reduce thinner content
translucent color Mix the ink to opaque
Plate too flat use deeper plate
Areas not rasterized Rasterize areas
wrong grid test different grid width
Pad too flat use a steeper pad
Surface porous use a new pad
too soft use a harder pad
Printing material dark background Use double printing or high-opacity ink
Surface too structured Use a steeper and harder pad
Miscellaneous Blade sags Rasterize plate

Register fluctuations

Caused Solution
Plate Position of individual print images incorrect new plate with corrected status
Pad not mounted centrally reposition
different forms Use a uniform pad shape
different hardnesses Use uniform pad hardness
pad stroke not identical for all colors Adjust pressure
Printing material Material is not warp-free use other material
Miscellaneous Recordings are not perfect Workpiece must not have any play
Rotary indexing table or similar runs inaccurately Check indexing
Recordings were not mounted correctly Check screws and pins

Distortion in the print image

Caused Solution
Plate Motive does not match the plate Check plate with film, if the film has slipped
Pad too small use a larger pad
too hard/soft test other hardness
Contact pressure too strong Reduce pad lift
different contact pressure adjust all tampons equally
wrong attachment point position differently
Printing material Material too soft/elastic Fix the part well, inflate the hollow body
deep sink marks Use pad assembly or special pad
Edges in the printing area pad replacement or monthly/special pad
Miscellaneous Recording unsuitable adapt to workpiece
Recording not stable Holder made of more stable material
Workpiece mounted at the wrong angle Change angle

Blurry print

Caused Solution
Ink too thick Dilute
too thin Mix with less thinner
too slow use faster thinner
Plate underexposed during exposure Expose layer by layer
too deep use flatter plate
Pad too soft use a harder pad
wrong shape other Form tests
Printing material Surface contaminated Pre-cleaning
severely deformed part pad assembly/use special pad
heavily structured surface insert hard, steep pad
Miscellaneous Recording not stable Holder made of more stable material
high cycle rate with large tampon volume Reduce cycle rate, waiting time before ink dispensing

No clean color gradient, wetting disturbance

Caused Solution
Ink too thick Dilute
too thin Mix with less thinner
not mixed homogeneously Mix homogeneously, allow to outgas
Plate incorrect etching depth check, if necessary new plate
wrong grid use a different grid
Pad Surface worn use a new pad
wrong shape other Form tests
Surface oily Clean/activate pad
Printing material Surface contaminated Pre-cleaning
Miscellaneous Paint contamination by grease, silicone... Reapply paint, clean materials

Overprintability in multi-color printing

Caused Solution
Ink too thick Dilute
too slow use faster thinner
Plate too deep make a flatter plate
wrong grid use a different grid
Pad Surface worn use a new pad
Printing material very smooth closed structure problematic are substances whose surface cannot be dissolved

Color does not match template

Caused Solution
Ink too thin mix again
wrong recipe check, reshuffle
too translucent mix with opaque base tones
Plate incorrect etching depth Check etching depth
wrong grid use a different grid
Pad Surface worn use a new pad
wrong shape Use a steeper, higher pad
Printing material dark printing material Double print or high opacity mixing
changing background colors with white underlay, double print, high opacity mixing

Paint splashes or threads

Caused Solution
Ink too thick Dilute
Color builds up on the tampon use faster thinner
Plate too deep make a flatter plate
wrong grid use a different grid
Pad Surface worn use a new pad
wrong shape try a different padshape
Printing material Surface becomes statically charged Integrate ionization into the machine
Miscellaneous Humidity too low increase
too high a clock rate Reduce printing speed
Cycle rate uneven ensure constant pressure flow

Fine lines converge

Caused Solution
Ink too thin mix again
too slow use faster thinner, blow
Plate too deep make a flatter plate
Pad unsuitable Pad should be steep and hard
Miscellaneous Pad stroke set too low Reduce stroke to prevent squeezing of the paint

Areas are not printed completely

Caused Solution
Ink too thin Remix ink with less thinner
Plate too flat make deeper plate
wrong grid plate with different screening
Pad wrong shape other Form tests
too soft test harder pad
worn use a new pad
Printing material structured surface use a hard, pointed pad
Surface contaminated Pre-cleaning
Miscellaneous blade sags Check plate depth, rasterize if necessary

Small air pockets visible

Caused Solution
Ink too thick Dilute
Plate Defects in the cliché make a new plate
Pad worn use a new pad
wrong shape choose a steeper shape
too soft choose a harder pad
Printing material static charge Ionize
Dust or other dirt particles Pre-cleaning, air shower or flame treatment
Miscellaneous damaged film new film
Dust during exposure Clean the foil in the exposure unit and film, if necessary, new plate
Environment not clean, dust Clean pad, possibly use integrated pad cleaning

Insufficient color adhesion

Caused Solution
Ink unsuitable color system Choose the appropriate ink for the substrate
Note drying times Adhesion tests only after the recommended time
Observe mixing ratios For 2K systems, adhere exactly to the quantities specified
Pad Surface oily Clean/activate the pad with solvent before printing
Printing material Surface contaminated Pre-cleaning
Miscellaneous Surface poorly pretreated Check/adjust pretreatment
wrong or no hardener Observe technical data sheets and quantity information
Surface poorly treated Check/adjust follow-up treatment

Color gloss not sufficient

Caused Solution
Ink Ink transfer too low deeper plate, double print
unsuitable color system Choose a brilliant system, use brilliant tones for mixing
Plate too flat make deeper plate
wrong grid Make plate with appropriate screening
Pad worn use a new pad
wrong shape choose a steeper shape
Printing material Material structure unsuitable Color and texture influence the degree of gloss
Material unsuitable choose a compatible color system

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